Dodge - Caliber - Workshop Manual - 2009 - 2009

Factory Workshop Manual Make Dodge Model Caliber Engine and year L4-2.4L (2009) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Sentry Key Immobilizer Module (SKREEM) - Description Alarm Module: Description and Operation Sentry Key Immobilizer Module (SKREEM) - Description DESCRIPTION When a PCM and the SKREEM are replaced at the same time, perform the following steps in order: 1. Program the new PCM. 2. Program the new SKREEM. 3. Replace all ignition keys and program them to the new SKREEM.See: Keyless Entry Module/Testing and Inspection/Programming and Relearning The Sentry Key REmote Entry Module (SKREEM) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM/WCM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system and the Tire Pressure Monitor (TPM) system. The SKREEM/WCM is located on the steering column, around the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM/WCM has an integral molded plastic halo-like antenna ring (3) that extends from one side. When the SKREEM/WCM is properly installed, the antenna ring is oriented around the ignition lock cylinder housing. A single connector (4) is located next to the antenna ring on the SKREEM/WCM housing (3). A molded plastic mounting tab (2) on the SKREEM/WCM housing secures the unit to the steering column. The SKREEM/WCM is connected to the vehicle electrical system through the instrument panel wire harness. The SKREEM/WCM cannot be adjusted or repaired. If faulty or damaged, the entire SKREEM unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Sentry Key Immobilizer Module (SKREEM) - Description > Page 8 Alarm Module: Description and Operation Sentry Key Immobilizer Module (SKREEM) - Operation OPERATION The Sentry Key REmote Entry Module (SKREEM), sometimes referred to as the Wireless Control Module (WCM), contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM/WCM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM/WCM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM/WCM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver and, if the vehicle is so equipped, the receiver for the Tire Pressure Monitoring (TPM) system. See: Body and Frame/Locks/Power Locks/Description and Operation/Power Locks - Description or See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Description and Operation/Tire Pressure Monitoring (TPM) - Description. The SKREEM/WCM communicates over the Controller Area Network (CAN) data bus with the Electro Mechanical Instrument Cluster (EMIC) (sometimes referred to as the Cab Compartment Node (CCN), the Powertrain Control Module (PCM), and/or the diagnostic scan tool. The SKREEM/WCM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM/WCM. For added system security, each SKREEM/WCM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM/WCM. Therefore, the Secret Key code is a common element that is found in every component of the Sentry Key Immobilizer System (SKIS). Another security code, called a PIN, is used to gain access to the SKREEM/WCM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Service and Repair See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Alarm System Transponder/Testing and Inspection The SKREEM/WCM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM during SKIS initialization. NOTE: After a SKREEM/WCM is replaced, the ignition/transponder keys need to be programmed to the new SKREEM/WCM. Follow the directions on the diagnostic scan tool. The transponder key for the SKREES/SKIM and the RKE will both be programmed during this operation. There is no need to program the fob of the key for RKE functionality once the transponder key is programmed to the new SKREEM/WCM. In the event that a SKREEM/WCM replacement is required, the Secret Key code can be transferred to the new SKREEM/WCM from the PCM using the diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM/WCM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM/WCM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On position, the SKREEM/WCM transmits an RF signal to the transponder in the ignition key. The SKREEM/WCM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM/WCM sends a valid key message to the PCM over the CAN data bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM/WCM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKREEM/WCM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKREEM/WCM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM/WCM also sends security indicator status messages to the EMIC/CCN over the CAN data bus to tell the EMIC/CCN how to operate the security indicator. The security indicator status message from the SKREEM/WCM tells the EMIC/CCN to turn the indicator on for about three seconds each time the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKREEM/WCM sends security indicator status messages to the EMIC/CCN to turn the indicator off, turn the indicator on, or to flash the indicator on and off. If the security indicator flashes or stays on solid after the bulb test, it signifies a SKIS fault. If the SKREEM/WCM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKREEM/WCM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM/WCM will also send messages to the EMIC/CCN to flash the security indicator whenever the Customer Learn programming mode is being utilized . See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Alarm System Transponder/Testing and Inspection The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM/WCM memory if a system malfunction is detected. The SKREEM/WCM can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) Removal Alarm Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Removal REMOVAL NOTE: The steering wheel does not have to be removed to service the SKREEM/WCM. NOTE: The Steering Column Control Module (SCCM) assembly, which consists of the left/right multi-function switches and the clockspring, does not have to be removed to service the SKREEM/WCM. There is an access hole in the top of the right multi-function switch to access the mounting screw (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the upper and lower steering column shrouds See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the SKREEM/WCM mounting screw (2) on the ignition lock assembly and separate the SKREEM/WCM (3) from the ignition lock assembly. 4. Disconnect the SKREEM/WCM electrical connector (4). 5. Remove SKREEM/WCM (1 and 3) from column (2). When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Keyless Entry Module/Testing and Inspection/Programming and Relearning. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) Removal > Page 11 - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) Removal > Page 12 Alarm Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Installation INSTALLATION When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Keyless Entry Module/Testing and Inspection/Programming and Relearning. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. 1. Position the SKREEM/WCM (3) on the ignition lock housing and install the retaining screw (2). 2. Connect the SKREEM/WCM electrical connector (4). NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated . See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Alarm System Transponder/Testing and Inspection 3. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 16 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY MODULE-SENTRY KEY REMOTE ENTRY/WCM - (INSTRUMENT PANEL) 8 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Keyless Entry Module: Initial Inspection and Diagnostic Overview REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic information. Refer to the appropriate wiring information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 19 Keyless Entry Module: Programming and Relearning SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 20 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal Keyless Entry Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Removal REMOVAL NOTE: The steering wheel does not have to be removed to service the SKREEM/WCM. NOTE: The Steering Column Control Module (SCCM) assembly, which consists of the left/right multi-function switches and the clockspring, does not have to be removed to service the SKREEM/WCM. There is an access hole in the top of the right multi-function switch to access the mounting screw (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the upper and lower steering column shrouds See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the SKREEM/WCM mounting screw (2) on the ignition lock assembly and separate the SKREEM/WCM (3) from the ignition lock assembly. 4. Disconnect the SKREEM/WCM electrical connector (4). 5. Remove SKREEM/WCM (1 and 3) from column (2). When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Testing and Inspection/Programming and Relearning. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 23 - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 24 Keyless Entry Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Installation INSTALLATION When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Testing and Inspection/Programming and Relearning. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. 1. Position the SKREEM/WCM (3) on the ignition lock housing and install the retaining screw (2). 2. Connect the SKREEM/WCM electrical connector (4). NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated . See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Alarm System Transponder/Testing and Inspection 3. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations Voice Activation Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 28 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 29 Voice Activation Module: Diagrams Connector - (INSTRUMENT PANEL) 22 WAY MODULE-HANDS FREE - (INSTRUMENT PANEL) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 34 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY MODULE-SENTRY KEY REMOTE ENTRY/WCM - (INSTRUMENT PANEL) 8 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Keyless Entry Module: Initial Inspection and Diagnostic Overview REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic information. Refer to the appropriate wiring information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 37 Keyless Entry Module: Programming and Relearning SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 38 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal Keyless Entry Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Removal REMOVAL NOTE: The steering wheel does not have to be removed to service the SKREEM/WCM. NOTE: The Steering Column Control Module (SCCM) assembly, which consists of the left/right multi-function switches and the clockspring, does not have to be removed to service the SKREEM/WCM. There is an access hole in the top of the right multi-function switch to access the mounting screw (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the upper and lower steering column shrouds See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the SKREEM/WCM mounting screw (2) on the ignition lock assembly and separate the SKREEM/WCM (3) from the ignition lock assembly. 4. Disconnect the SKREEM/WCM electrical connector (4). 5. Remove SKREEM/WCM (1 and 3) from column (2). When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Testing and Inspection/Programming and Relearning. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 41 - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 42 Keyless Entry Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Installation INSTALLATION When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Testing and Inspection/Programming and Relearning. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. 1. Position the SKREEM/WCM (3) on the ignition lock housing and install the retaining screw (2). 2. Connect the SKREEM/WCM electrical connector (4). NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated . See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Alarm System Transponder/Testing and Inspection 3. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 46 Seat Heater Control Module: Diagrams Connector - (DRIVER SEAT) 10 WAY MODULE-HEATED SEATS - (DRIVER SEAT) 10 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description Seat Heater Control Module: Description and Operation Heated Seat Module - Description DESCRIPTION The heated seat module (2) is located under the left front seat. It has a single electrical connector (1) and a push pin style retainer that secures it to the seat pan. The module can be accessed from under the front left seat with the seat in the full back position. The heated seat module is a microprocessor designed to use the Local Interface Network (LIN) data bus messages from the instrument cluster also known as the Cabin Compartment Node (CCN). The CCN receives inputs from the heated seat switches and in turn signals the heated seat module to operate the heated seat elements for both front seats. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description > Page 49 Seat Heater Control Module: Description and Operation Heated Seat Module - Operation OPERATION The heated seat module operates on fused battery current received from the ignition switch. The module is grounded to the body at all times through the electrical connector. Inputs to the module include Local Interface Network (LIN) data bus messages and standard hardwired 12 volt power and ground. In response to the LIN inputs the heated seat module will control the battery current to the appropriate heated seat elements. When a heated seat switch LIN data bus signal is received by the heated seat module, the module energizes the selected heated seat element. The Low heat set point is about 38° C (100.4° F), and the High heat set point is about 42° C (107.6° F). In addition to operating the heated seat elements, the heated seat module sends LED illumination messages to the CCN via the LIN data bus. The CCN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. If the heated seat module detects a heated seat element OPEN or SHORT circuit, it will record and store the appropriate diagnostic trouble code (DTC). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 50 Seat Heater Control Module: Testing and Inspection HEATED SEAT MODULE In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal Seat Heater Control Module: Service and Repair Heated Seat Module - Removal REMOVAL CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Position the left front seat to the full rearward position. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the wire harness connector (4) from the heated seat module (3). 4. Unsnap the heated seat module retaining tab (2) from the seat pan (1). 5. Remove the heated seat module (3) from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal > Page 53 Seat Heater Control Module: Service and Repair Heated Seat Module - Installation INSTALLATION CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Install the heated seat module (3) into the vehicle. 2. Position the retaining tab (2) with the mounting hole in the seat pan (1). Firmly apply even pressure to the module (3) until the mounting tab is fully seated. 3. Connect the wire harness connector (4) to the heated seat module (3). 4. Connect the battery negative cable. 5. Check for proper heated seat system operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Trailer Tow Lamp Relay (Trailer Tow) 4 Way Trailer Towing Relay: Diagrams Trailer Tow Lamp Relay (Trailer Tow) 4 Way Connector - (TRAILER TOW) 4 WAY RELAY-TRAILER TOW BRAKE LAMP - (TRAILER TOW) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Trailer Tow Lamp Relay (Trailer Tow) 4 Way > Page 59 Trailer Towing Relay: Diagrams Left Trailer Tow Relay (Trailer Tow) 5 Way Connector - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW-LEFT - (TRAILER TOW) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Trailer Tow Lamp Relay (Trailer Tow) 4 Way > Page 60 Trailer Towing Relay: Diagrams Right Trailer Tow Relay (Trailer Tow) 5 Way Connector - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW-RIGHT - (TRAILER TOW) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 65 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 66 Electronic Brake Control Module: Diagrams Connector - (ENGINE COMPARTMENT) 47 WAY MODULE-ANTI-LOCK BRAKES - (ENGINE COMPARTMENT) 47 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 67 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module - Description Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Description DESCRIPTION The Antilock Brake Module (ABM) is a microprocessor-based device which monitors the antilock brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop or when in a traction control or Electronic Stability Program (ESP) situation. The ABM utilizes a 47-way electrical connector on the vehicle wiring harness. The power source for the ABM is through the ignition switch in the RUN or ON position. The ABM (1) is mounted to the HCU (2) as part of the Integrated Control Unit (ICU). The ICU is located in the engine compartment on the inboard side of the right body frame rail behind the strut tower. For information on the ICU, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Description and Operation/Integrated Control Unit (ICU) - Description - DESCRIPTION). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module - Description > Page 70 Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Operation OPERATION The primary functions of the Antilock Brake Module (ABM) are to: - Monitor the Antilock Brake System (ABS) and Electronic Stability Program (ESP) for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in ABS or traction control mode. - Modulates fluid pressure to the wheel brakes to control vehicle yaw rate in ESP mode. - Store diagnostic information. - Provide communication to the scan tool while in diagnostic mode. - Illuminate the amber ABS indicator in the instrument cluster. - Illuminate the yellow ESP/BAS indicator in the instrument cluster (if equipped). The ABM constantly monitors the ABS and ESP (if equipped) for proper operation. If the ABM detects a fault, it will turn on the amber ABS and yellow ESP/BAS indicators and disable the ABS or ESP if so equipped. The normal base braking system will remain operational at that time. The ABM continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the ABM commands the ABM solenoid coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The ABM continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Radiator Cooling Fan Module C1 (Engine Compartment) 2 Way Radiator Cooling Fan Control Module: Diagrams Radiator Cooling Fan Module C1 (Engine Compartment) 2 Way Connector C1 - (ENGINE COMPARTMENT) 2 WAY FAN MODULE-RADIATOR COOLING - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Radiator Cooling Fan Module C1 (Engine Compartment) 2 Way > Page 77 Radiator Cooling Fan Control Module: Diagrams Radiator Cooling Fan Module C2 (Engine Compartment) 2 Way Connector C2 - (ENGINE COMPARTMENT) 2 WAY FAN MODULE-RADIATOR COOLING - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Radiator Fan Relays are located in the Fuse/Relay block. Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Low/High Connector - (IN F/RB) RELAY-RADIATOR FAN-LOW/HIGH - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High > Page 83 Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Medium/High Connector - (IN F/RB) RELAY-RADIATOR FAN-MEDIUM/HIGH - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High > Page 84 Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Series/Parallel Connector - (IN F/RB) RELAY-RADIATOR FAN-SERIES/PARALLEL - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation Fuel Gauge Module: Customer Interest Instruments - Fuel Gauge Fluctuation NUMBER: 08-024-10 GROUP: Electrical DATE: September 22, 2010 SUBJECT: Fuel Gauge Fluctuation OVERVIEW: This Bulletin involves replacing the fuel sending unit, clocking the fuel module and installing a fuel jumper hose. MODELS: 2007 - 2010 (PM) Caliber (FWD Only) 2007 - 2010 (MK) Compass / Patriot (FWD Only) SYMPTOM/CONDITION: The customer may complain that the fuel gauge is not accurate or fluctuates at 3/4 of a tank or above. DIAGNOSIS: Some customers may experience the condition described above. Preform the repair as described below. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Removal > Front Wheel Drive Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 94 NOTE: Mark the sending unit at the 4:00 position with 12:00 pointing to the rear of the vehicle. 2. Remove the fuel pump sending unit from the Pump module. 3. Install New Sender to the Fuel Pump Module. 4. Install Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Installation > Front Wheel Drive NOTE: Clock the Fuel Module to the 2:00 position Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 95 5. Install the jumper hose kit 6. Re-Connect battery 7. Start vehicle and check for leaks 8. Re-install Fuel Pump Cover 9. Re-install padding and rear seat bottom 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation Fuel Gauge Module: All Technical Service Bulletins Instruments - Fuel Gauge Fluctuation NUMBER: 08-024-10 GROUP: Electrical DATE: September 22, 2010 SUBJECT: Fuel Gauge Fluctuation OVERVIEW: This Bulletin involves replacing the fuel sending unit, clocking the fuel module and installing a fuel jumper hose. MODELS: 2007 - 2010 (PM) Caliber (FWD Only) 2007 - 2010 (MK) Compass / Patriot (FWD Only) SYMPTOM/CONDITION: The customer may complain that the fuel gauge is not accurate or fluctuates at 3/4 of a tank or above. DIAGNOSIS: Some customers may experience the condition described above. Preform the repair as described below. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Removal > Front Wheel Drive Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 101 NOTE: Mark the sending unit at the 4:00 position with 12:00 pointing to the rear of the vehicle. 2. Remove the fuel pump sending unit from the Pump module. 3. Install New Sender to the Fuel Pump Module. 4. Install Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Installation > Front Wheel Drive NOTE: Clock the Fuel Module to the 2:00 position Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 102 5. Install the jumper hose kit 6. Re-Connect battery 7. Start vehicle and check for leaks 8. Re-install Fuel Pump Cover 9. Re-install padding and rear seat bottom 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Service and Repair > Horn Relay - Removal Horn Relay: Service and Repair Horn Relay - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power Module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Service and Repair > Horn Relay - Removal > Page 108 Horn Relay: Service and Repair Horn Relay - Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 Power Distribution Module: Locations Totally Integrated Power Module C1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 114 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 115 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 116 Power Distribution Module: Locations Totally Integrated Power Module C2 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 117 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 118 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 119 Power Distribution Module: Locations Totally Integrated Power Module C3 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 120 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 121 Power Distribution Module: Locations Totally Integrated Power Module C4 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 122 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 123 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 124 Power Distribution Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 125 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 126 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 127 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 128 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 129 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 130 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 131 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 132 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 133 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 134 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 135 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 136 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 137 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 138 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 139 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 140 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 141 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 142 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 143 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 144 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 145 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 146 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 147 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 148 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 149 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 150 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way Power Distribution Module: Diagrams Inverter Module (Instrument Panel) 9 Way Connector (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 153 Power Distribution Module: Diagrams Totally Integrated Power Module C1 (Engine Compartment) 13 Way Connector C1 - (ENGINE COMPARTMENT) 13 WAY C1 TIPM - (ENGINE COMPARTMENT) 13 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 154 Power Distribution Module: Diagrams Totally Integrated Power Module C2 (Engine Compartment) 14 Way Connector C2 - (ENGINE COMPARTMENT) 14 WAY C2 TIPM - (ENGINE COMPARTMENT) 14 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 155 Power Distribution Module: Diagrams Totally Integrated Power Module C3 (Engine Compartment) 16 Way Connector C3 - (ENGINE COMPARTMENT) 16 WAY C3 TIPM - (ENGINE COMPARTMENT) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 156 Power Distribution Module: Diagrams Inverter Module (Instrument Panel) 9 Way Connector (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY Totally Integrated Power Module C1 (Engine Compartment) 13 Way Connector C1 - (ENGINE COMPARTMENT) 13 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 157 C1 TIPM - (ENGINE COMPARTMENT) 13 WAY Totally Integrated Power Module C2 (Engine Compartment) 14 Way Connector C2 - (ENGINE COMPARTMENT) 14 WAY C2 TIPM - (ENGINE COMPARTMENT) 14 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 158 Totally Integrated Power Module C3 (Engine Compartment) 16 Way Connector C3 - (ENGINE COMPARTMENT) 16 WAY C3 TIPM - (ENGINE COMPARTMENT) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 159 Totally Integrated Power Module C4 (Engine Compartment) 10 Way Connector C4 - (ENGINE COMPARTMENT) 10 WAY C4 TIPM - (ENGINE COMPARTMENT) 10 WAY Totally Integrated Power Module C5 (Engine Compartment) 14 Way Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 160 Connector C5 - (ENGINE COMPARTMENT) 14 WAY C5 TIPM - (ENGINE COMPARTMENT) 14 WAY Totally Integrated Power Module C6 (Engine Compartment) 13 Way Connector C6 - (ENGINE COMPARTMENT) 13 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 161 C6 TIPM - (ENGINE COMPARTMENT) 13 WAY Totally Integrated Power Module C7 (Engine Compartment) 22 Way Connector C7 - (ENGINE COMPARTMENT) 22 WAY C7 TIPM - (ENGINE COMPARTMENT) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 162 Totally Integrated Power Module C8 (Engine Compartment) 22 Way Connector C8 - (ENGINE COMPARTMENT) 22 WAY C8 TIPM - (ENGINE COMPARTMENT) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 163 Totally Integrated Power Module C9 (Battery Feed To TIPM) 1 Way Connector C9 - (BATTERY FEED TO TIPM) 1 WAY C9 TIPM - (BATTERY FEED TO TIPM) 1 WAY Totally Integrated Power Module C10 (Engine Compartment) 8 Way Connector C10 - (ENGINE COMPARTMENT) 8 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 164 C10 TIPM - (ENGINE COMPARTMENT) 8 WAY Totally Integrated Power Module C11 (Engine Compartment) 22 Way Connector C11 - (ENGINE COMPARTMENT) 22 WAY C11 TIPM - (ENGINE COMPARTMENT) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 165 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description Power Distribution Module: Description and Operation Power Inverter Module - Description DESCRIPTION The inverter module is located in the instrument panel. The A/C outlet is mounted in the center console. The inverter module provides A/C power for user accessories. The inverter converts the 12 Volt DC from the battery system to a 110 Volt AC output. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description > Page 168 Power Distribution Module: Description and Operation Power Inverter Module - Operation OPERATION The AC power outlet receives 12 volts from the Totally Integrated Power Module (TIPM) and passes it as an enable signal to the inverter module. The inverter module also receives 12 volts via the TIPM and inverts this to a 110 volt AC output. The enable signal received from the power outlet enables the inverter to convert the received voltage and pass it to the power outlet to power external devices. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description > Page 169 Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM) (1). The molded plastic TIPM housing is located in the left front corner of the engine compartment, just behind the air cleaner housing and the battery. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse and relay layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the left inner fender well an indexing pin and one screw. All of the TIPM outputs are through the integral engine compartment wire harness. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description > Page 170 Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Operation OPERATION All of the current from the generator cable connection goes to the battery through a 10 gauge fusible link that is secured with a nut to the positive battery terminal at the starter. Internal connection of all the Totally Integrated Power Module (TIPM) circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fusible link, fuses and relays are available for service replacement. The TIPM unit cannot be repaired and is only serviced as a unit with the engine compartment wire harness. If the TIPM is inoperative or damaged, the engine compartment wire harness assembly must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Power Distribution Module: Component Tests and General Diagnostics INVERTER MODULE For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 110 VOLT POWER OUTLET DIAGNOSIS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 173 Power Distribution Module: Programming and Relearning PROGRAMMING 1. Install a battery charger. 2. Verify that the charging rate provides approximately 13.5 volts. NOTE: Do not allow the charger to time out during the reconfiguration process. Set the battery charger timer (if so equipped) to continuous charge. 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 5. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 6. Select "ECU View". 7. Select "TIPMCGW" or "FCMCGW". 8. Select "MISC". 9. Select "Restore Vehicle Configuration". 10. Follow prompts on StarSCAN to complete the reconfigure procedure. 11. Once complete, Wait one minute and turn the ignition key to the "OFF" position. 12. Remove the StarSCAN unit, cable and charger from the vehicle. 13. Verify proper operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal Power Distribution Module: Service and Repair Power Inverter Module - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the shift bezel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Removal 3. Remove the center bezel from the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 4. Remove the fasteners from the mounting brackets of the inverter module. 5. Disconnect the electrical connectors and remove the inverter module. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 176 Power Distribution Module: Service and Repair Power Inverter Module - Installation INSTALLATION 1. Connect the electrical connectors to the inverter module. 2. Install the fasteners to the mounting brackets. 3. Install the center bezel to the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Install the shift bezel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Installation. 5. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 177 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) - Removal REMOVAL The TIPM (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. Refer to Wiring Diagrams for more information on the locations of the affected connectors. 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect each of the engine compartment wire harness connectors. 4. Remove the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. 5. Disengage each of the retainers that secure the engine compartment wire harness to the vehicle body and chassis components. 6. Disengage and remove the TIPM housing from its mounting bracket. 7. Remove the TIPM and the engine compartment wire harness from the engine compartment as a unit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 178 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) Installation INSTALLATION CAUTION: The original Cabin Compartment Node (CCN) and Powertrain Control Module (PCM) must be installed and functioning properly prior to powering up the new Totally Integrated Power Module (TIPM). The TIPM receives vehicle configuration data from the CCN and Vehicle Identification Number (VIN) information from the PCM. If configuration information becomes lost or corrupted, the data can be obtained from DealerCONNECT The Totally Integrated Power Module (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. 1. Position the TIPM in the engine compartment. 2. Align the TIPM on its mounting bracket and install. 3. Route the engine compartment wire harness from the TIPM through the engine compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. Refer to Wiring Diagrams for more information on the harness routing and retainer locations. 4. Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. Refer to Wiring Diagrams for more information on the ground eyelet locations. 5. Reconnect each of the engine compartment wire harness connectors. Refer to Wiring Diagrams for more information on the locations of the affected connectors. 6. Torque nut retaining positive battery cable at TIPM to 96 - 141 Nm (85 - 130 in. lbs.). 7. Reconnect the battery negative cable. 8. Close hood. 9. Verify vehicle and system operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay - Removal Power Distribution Relay: Service and Repair Relay - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay - Removal > Page 183 Power Distribution Relay: Service and Repair Relay - Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 187 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 188 Relay Box: Application and ID Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 199 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 200 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 201 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 202 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 203 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 204 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 205 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 206 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 207 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 208 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 209 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: Recalls Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P0139/P0571 Set NUMBER: 18-018-09 GROUP: Vehicle Performance DATE: June 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For Diagnostic Trouble Code P0139 Or P0571 Is Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey 2009 (JS) Sebring/Avenger/Sebring Convertible 2009 (PM) Caliber 2009 (MK) Compass/Patriot NOTE: This bulletin applies to: - 2009 JS vehicles equipped with a 2.0L/2.4L Engine (Sales Code ECN or EDG or ED3) built before July 27, 2009 (MDH 0727XX) - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before July 27, 2009 (MDH 0727XX) - 2009 PM/MK vehicles equipped with a 1.8L, 2.0L or 2.4L engines (Sales Codes EBA, ECN and ED3) built before July 10, 2009 (MDH 0710XX) SYMPTOM/CONDITION: Some customers may experience a MIL illumination. The MIL is for P0139 - 02 Sensor 1/2 Slow Response. Further investigation by the technician may also find DTC P0571. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other then the ones listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set > Page 219 If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0139/P0571 Set NUMBER: 18-018-09 GROUP: Vehicle Performance DATE: June 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For Diagnostic Trouble Code P0139 Or P0571 Is Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey 2009 (JS) Sebring/Avenger/Sebring Convertible 2009 (PM) Caliber 2009 (MK) Compass/Patriot NOTE: This bulletin applies to: - 2009 JS vehicles equipped with a 2.0L/2.4L Engine (Sales Code ECN or EDG or ED3) built before July 27, 2009 (MDH 0727XX) - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before July 27, 2009 (MDH 0727XX) - 2009 PM/MK vehicles equipped with a 1.8L, 2.0L or 2.4L engines (Sales Codes EBA, ECN and ED3) built before July 10, 2009 (MDH 0710XX) SYMPTOM/CONDITION: Some customers may experience a MIL illumination. The MIL is for P0139 - 02 Sensor 1/2 Slow Response. Further investigation by the technician may also find DTC P0571. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other then the ones listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set > Page 225 If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 230 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 231 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 232 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 233 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 234 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 235 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 236 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 237 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 238 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 239 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 240 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: All Technical Service Bulletins Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0139/P0571 Set NUMBER: 18-018-09 GROUP: Vehicle Performance DATE: June 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For Diagnostic Trouble Code P0139 Or P0571 Is Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey 2009 (JS) Sebring/Avenger/Sebring Convertible 2009 (PM) Caliber 2009 (MK) Compass/Patriot NOTE: This bulletin applies to: - 2009 JS vehicles equipped with a 2.0L/2.4L Engine (Sales Code ECN or EDG or ED3) built before July 27, 2009 (MDH 0727XX) - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before July 27, 2009 (MDH 0727XX) - 2009 PM/MK vehicles equipped with a 1.8L, 2.0L or 2.4L engines (Sales Codes EBA, ECN and ED3) built before July 10, 2009 (MDH 0710XX) SYMPTOM/CONDITION: Some customers may experience a MIL illumination. The MIL is for P0139 - 02 Sensor 1/2 Slow Response. Further investigation by the technician may also find DTC P0571. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other then the ones listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set > Page 250 If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 256 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 257 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 258 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 259 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 260 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 261 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 262 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 263 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 264 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 265 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 266 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: All Technical Service Bulletins Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 271 Engine Control Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 272 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way Engine Control Module: Diagrams Powertrain Control Module C1 (Engine Compartment) 58 Way Connector C1 (GAS) - (ENGINE COMPARTMENT) 58 WAY MODULE-POWERTRAIN CONTROL (GAS) - (ENGINE COMPARTMENT) 58 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 275 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 276 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 277 Engine Control Module: Diagrams Powertrain Control Module C2 (Engine Compartment) 96 Way Connector C2 (GAS) - (ENGINE COMPARTMENT) 96 WAY MODULE-POWERTRAIN CONTROL (GAS) - (ENGINE COMPARTMENT) 96 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 278 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 279 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 280 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description Engine Control Module: Description and Operation Powertrain Control Module - Description Sensor Return - PCM Input SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). PCM Ground PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded separately from the ground pins. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 283 Engine Control Module: Description and Operation Powertrain Control Module - Operation Operation OPERATION The PCM supplies two regulated 5 volts supplies - a 5V primary and a 5V secondary (auxiliary) to the following sensors: - Camshaft Position Sensor (5V secondary) - Crankshaft Position Sensor (5V primary) - EGR Position feedback sensor (5V secondary) (if equipped) - Engine coolant temperature sensor (connected to 5V internal via a pull-up resistor) - Inlet Air Temperature Sensor (connected to 5V internal via a pullup resistor) - Knock sensor (connected to 5V internal via a pullup resistor) - Manifold absolute pressure sensor (5V secondary) - Oil Pressure Switch (connected to 5V internal via pullup resistor) - Pedal Value Sensor #1 (5V Primary) - Pedal Value Sensor #2 (5V Secondary) - SRV Position Feedback Sensor (5V Secondary) - Throttle Position Sensors (5V Primary) - Variable Line Pressure Sensor (5V Secondary) Powertrain Control Module POWERTRAIN CONTROL MODULE The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. NOTE: PCM Inputs: - Air Conditioning Controls - Battery Voltage - Brake Switch - Camshaft Position Sensor - Clutch Upstop Switch - Clutch Interlock - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor (Bus message) - Ignition Switch - Intake Air Temperature Sensor - Knock Sensor - Evaporative System Integrity Monitor Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 284 - Manifold Absolute Pressure (MAP) Sensor - Oil Pressure Switch - Oxygen Sensors - Power Steering Pressure Switch - Speed Control Switches - Vehicle Speed Sensor (MTX-equipped models) NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Charging Indicator Lamp (Bus Message) - Proportional Purge Solenoid - Fuel Injectors - Generator Field - Ignition Coils - Malfunction Indicator (Check Engine) Lamp (Bus Message) - Manifold Flow Valve - Oxygen Sensors Heater Controls - Variable Valve Timing - Vehicle Speed (Manual Transmission) Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and EVAP canister purge operation. The PCM also determines the appropriate transmission shift schedule and shift points, depending on the present operating conditions and driver demand. The PCM regulates the cooling fan, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM also performs diagnostics. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. - Battery voltage - Coolant temperature - Exhaust gas content (oxygen sensor) - Engine speed (crankshaft position sensor) - Intake air temperature - Manifold absolute pressure - Throttle position The PCM adjusts ignition timing based on the following inputs. - Coolant temperature - Engine speed (crankshaft position sensor) - Knock sensor - Manifold absolute pressure - Throttle position - Transmission gear selection (park/neutral switch) - Intake air temperature The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs. - Air conditioning sense - Battery voltage - Brake switch - Coolant temperature - Engine speed (crankshaft position sensor) - Engine run time - Manifold absolute pressure - Power steering pressure switch - Throttle position - Transmission gear selection (park/neutral switch) - Vehicle distance (speed) The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive the signal within approximately 1 second of engine cranking, it deactivates the fuel pump. When these are deactivated, power is shut off to the fuel injectors, ignition coils, oxygen sensor heating elements and fuel pump. The PCM contains a voltage converter that changes battery voltage to a regulated 5 volts direct current to power the camshaft position sensor, crankshaft position sensor, manifold absolute pressure sensor, throttle position sensor, A/C pressure switch, A/C pressure transducer, and vehicle speed sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures TCM Initialization TRANSMISSION CONTROL MODULE INITIALIZATION NOTE: Refer to the following table when the Transmission Control Module (TCM) and/or transaxle has been replaced to determine if the TCM memory must be erased. INITIAL LEARN (BRAND-NEW MODULE, MEMORY ALREADY CLEAR) Battery must be connected. If the Totally Integrated Power Module (TIPM) is to be configured, configure the TIPM and then turn ignition key to OFF/LOCKED briefly, then back to RUN. The shifter must be in PARK or NEUTRAL, engine not running. 1. Turn the ignition key to RUN for 4 seconds to allow reading of new values. 2. Turn ignition key to OFF/LOCKED for 2 seconds to allow storing new values in EEROM. 3. Turn the ignition key to RUN, with scan tool clear DTCs. 4. Turn ignition key to OFF/LOCKED for 2 seconds. 5. After at least 7 seconds, read DTCs. 6. If DTCs resets See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Testing and Inspection RELEARN, AFTER REPLACING A TRANSAXLE 1. Turn ignition key to RUN. 2. Clear learning memory using the scan tool. 3. Turn the ignition key to OFF/LOCKED for 2 seconds. 4. Turn the ignition key to RUN Clear DTCs. 5. Turn the ignition key to OFF/LOCKED for 2 seconds. 6. Turn ignition key to RUN. 7. After at least 7 seconds, read DTCs. 8. If DTCs resets See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Testing and Inspection PCM/TCM Reprogramming PCM / TCM PROGRAMMING PCM / TCM FLASH PROGRAMING This procedure will need to be done when one or more of the following situations are true: 1. A vehicle's Powertrain Control Module (PCM) has been replaced. 2. A diagnostic trouble code (DTC) is set P1602 - PCM Not Programmed. 3. An updated calibration or software release is available for either the PCM or TCM ECUs. This procedure assumes that the wiTECH(TM) Vehicle Connection Interface (VCI) pod, StarSCAN(R) and StarMOBILE(R) devices are configured to your dealership's network with either a wired or wireless connection. The wiTECH(TM) VCI pod, StarSCAN(R) and StarMOBILE(R) must also be running at the latest operating system and software release level. For more help on how to network your StarSCAN(R) or StarMOBILE(R) reference the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the Download Center. For the wiTECH(TM) VCI pod use the "HELP" tab in the wiTECH(TM) Diagnostic Application. Table of contents 1. SECTION 1 - PCM / TCM FLASH PROCEDURE SECTION 1 - PCM / TCM FLASH PROCEDURE 2. REQUIRED TOOLS/EQUIPMENT REQUIRED TOOLS/EQUIPMENT: 3. TECH TIPS and INFORMATION TECH TIPS and INFORMATION: 4. PARTS REQUIRED PARTS REQUIRED Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 287 SECTION 1 - PCM / TCM FLASH PROCEDURE If using StarSCAN(R) or StarMOBILE(R) Desktop Client. Go To REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client If using StarMOBILE(R) Standalone Diagnostic Mode. Go To REPAIR PROCEDURE wiTECH(TM) Diagnostic Application REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the StarSCAN(R) or StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power on the StarSCAN(R) or StarMOBILE(R). If the StarMOBILE(R) is being used, launch the StarMOBILE(R) Desktop Client and connect to the appropriate StarMOBILE(R) device. 4. Retrieve the old ECU part number. From the tool's Home screen, a. Select "ECU View" b. Select "PCM/ECM" c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the Flash PCM/ECM screen for later reference. 5. Program the ECU as follows: a. Using the StarSCAN(R) / StarMOBILE(R) at the Home screen, select "ECU View" b. Select "PCM/ECM" c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File" and follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 4e, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. g. Select "Download to Scantool" h. Once the download is complete, select "Close" and then "Back" i. Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. j. When the PCM/ECM update is complete, select "OK" k. Verify that the part number at the top of the Flash PCM/ECM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 6. Continue to SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced. 7. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See Section 3 SECTION 3 - AUTHORIZED MODIFICATION LABEL for details). REPAIR PROCEDURE - wiTECH(TM) Diagnostic Application NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the wiTECH(TM) Vehicle Connection Interface (VCI) pod to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Launch the wiTECH(TM) Diagnostic Application and connect to the appropriate wiTECH(TM) device. 4. From the wiTECH(TM) Diagnostic Application Home screen, a. Select "HELP" b. Select "HELP CONTENTS" c. Follow the correct "HELP TOPIC" for the ECU being programmed SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES NOTE: Find the PCM/TCM Type for the vehicle, read and write down the steps, and then go to the step by step instructions for additional information on how to perform these procedures. STEP-BY-STEP INSTRUCTIONS If an EDC16-U31 PCM/ECM (2.0L) was replaced, perform the following additional steps and/or routines: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 288 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Program Variant Code If an EDC16-C2 PCM/ECM (2.2L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. IMA Rapid Calibration Test - Only on 06 PT AND up 4. Injector Quantity Adjustment - Only on 06 PT AND up If an EDC16-CP31 (3.0L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Diesel Particulate Filter (Used) Learning 4. NOx Catalyst (New) Initialization 5. Injector Quantity Adjustment 6. IMA Rapid Calibration Test 7. Fuel Mean Value Adaptation Initialization 8. Exhaust Throttle Plate Adaptive Learn Position If an EDC16-CP31-2 (2.8L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Injector Quantity Adjustment 4. Program Variant Code 5. ECU Replacement With Value Transfer if the ECU to be replaced is still responsive 6. ECU Replacement Without Value Transfer - if the ECU to be replaced is NOT responsive 7. Fuel Mean Value Adaptation Initialization 8. IMA Rapid Calibration Test 9. Set Oil Dilution Mass Value If a CM849 PCM/ECM (5.9L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped If a CM2100 PCM/ECM (6.7l) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Enable / Disable Vehicle Features - need to enable features 4. Injector Quantity Adjustment 5. Reset Regenerative Filter Timers 6. Mobile DeSoot - NO Minimum Required Soot Load If an Asian TCM was replaced, perform the following additional steps and/or routines: If an EATX TCM was replaced, perform the following additional steps and/or routines: If an NGC3 TCM ONLY was replaced, perform the following additional steps and/or routines: If an NGC4 TCM ONLY was replaced, perform the following additional steps and/or routines: 1. Quicklearn If an EGS TCM was replaced, perform the following additional steps and/or routines: 1. Initialize EGS STEP-BY-STEP INSTRUCTIONS Check PCM/ECM VIN Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 289 From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Check PCM/ECM VIN" and follow the on screen instructions. - When complete, select "Finish" Diesel Particulate Filter (Used) Learning From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Diesel Particulate Filter (Used) Learning" and follow the on screen instructions. - When complete, select "Finish" ECU Replacement with Value Transfer From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "ECU Replacement with Value Transfer" and follow the on screen instructions. - When complete, select "Finish" ECU Replacement without Value Transfer From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "ECU Replacement without Value Transfer" and follow the on screen instructions. - When complete, select "Finish" Enable / Disable Vehicle Features From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Enable / Disable Vehicle Features" and follow the on screen instructions. - When complete, select "Finish" Exhaust Throttle Plate Adaptive Learn Position From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Exhaust Throttle Plate Adaptive Learn Position" and follow the on screen instructions. - When complete, select "Finish" Fuel Mean Value Adaptation Initialization From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Fuel Mean Value Adaptation Initialization" and follow the on screen instructions. - When complete, select "Finish" IMA Rapid Calibration From the "Home" screen, select "ECU View" Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 290 - Select "PCM/ECM" - Select "Misc. Functions" - Select "IMA Rapid Calibration Test" and follow the on screen instructions. - When complete, select "Finish" Initialize EGS From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Initialize EGS" and follow the on screen instructions. - When complete, select "Finish" Injector Quantity Adjustment From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Injector Quantity Adjustment" and follow the on screen instructions. - When complete, select "Finish" Mobile DeSoot - NO Minimum Required Soot Load From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Mobile DeSoot - NO Minimum Required Soot Load" and follow the on screen instructions. - When complete, select "Finish" NOx Catalyst (New) Initialization From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "NOx Catalyst (New) Initialization" and follow the on screen instructions. - When complete, select "Finish" PCM/ECM Replaced The vehicle pin (Personal Identification Number) will be required to complete the routine. This information may be obtained in three ways: 1. The original selling invoice 2. DealerCONNECT > Parts > Key Codes 3. Contacting the District Manager. From the "Home" screen, select "ECU View" - Select "WIN" - Select "Misc. Functions" - Select "PCM/ECM Replaced" and follow the on screen instructions. - When complete, select "Finish" Program Variant Code From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Program Variant Code" and follow the on screen instructions. - When complete, select "Finish" Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 291 Quicklearn From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Quicklearn" and follow the on screen instructions. - When complete, select "Finish" Reset Regenerative Filter Timers From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Reset Regenerative Filter Times" and follow the on screen instructions. - When complete, select "Finish" Set Oil Dilution Mass Value From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Set Oil Dilution Mass Value" and follow the on screen instructions. - When complete, select "Finish" SECTION 3 - AUTHORIZED MODIFICATION LABEL NOTE: The following step is required by law when reprogramming a PCM/ECM and/or TCM. Type the necessary information on the "Authorized Modification Label" and attach near the VECI label. 1. Powertrain Control / Transmission Control Module Part Numbers (Insert P/Ns) Used 2. Change Authority: TSB XX--XX 3. Dealer Code: XXXXX 4. Date: XX-XX-XX REQUIRED TOOLS/EQUIPMENT: TECH TIPS and INFORMATION: CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 292 1. The wiTECH(TM) Diagnostic Application is the preferred method for flashing any Chrysler vehicle ECU. For more information, training tutorials are available under the "HELP" tab in the wiTECH(TM) Diagnostic Application, under the 'Training Aids' link. 2. To use the StarMOBILE(R) in Pass-Through Mode requires that your StarMOBILE(R) is connected to the dealerships network via a wired or wireless connection. For more information on how to use the StarMOBILE in Pass-Through Mode see the StarMOBILE(R) training tutorials available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Training Aids' link, under the 'Training Aids' link. 3. If the flash process is interrupted or aborted, the flash should be restarted. 4. Due to the PCM/ECM / TCM programming procedure, a DTC may be set in other ECUs within the vehicle. Some DTCs may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 5. Do not allow the battery charger to time out or the charging rate to climb above 13.5 Volts during the flash process. 6. The StarSCAN(R) and StarMOBILE(R) diagnostic tools fully support Internet connectivity and must be configured for your dealership's network. For help on setting up your StarSCAN(R) / StarMOBILE(R) for the dealership's network, refer to the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the download center. 7. The operating software in the StarSCAN(R) and StarMOBILE(R) must be programmed with the latest software release level. The software level is visible in the blue header at the top of the StarSCAN(R) and StarMOBILE(R) Desktop Client screens. For instructions on how to update your scan tool, refer to the StarSCAN(R) / StarMOBILE(R) Software Update guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the download center. PARTS REQUIRED Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 293 The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 294 If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 295 Engine Control Module: Removal and Replacement Powertrain Control Module - Removal REMOVAL USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. To avoid possible voltage spike damage to PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable. 2. Unlock and disconnect the electrical connectors from PCM. 3. Remove the air cleaner box. 4. Remove the three mounting bolts. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 296 5. Tip module out and remove from bracket. Powertrain Control Module - Installation INSTALLATION USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Tip module into bracket. 2. Install three mounting bolts and tighten to 9 Nm (80 in. lbs.) torque. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 297 3. Check pins in electrical connectors for damage. Repair as necessary. 4. Connect electrical connectors and lock. 5. Install air cleaner box. 6. Connect negative battery cable. 7. Use the scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Main Relay is located in the Fuse/Relay block. Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 301 Main Relay (Computer/Fuel System): Diagrams Connector - (IN F/RB) RELAY-MAIN - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Main Relay is located in the Fuse/Relay block. Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 306 Main Relay (Computer/Fuel System): Diagrams Connector - (IN F/RB) RELAY-MAIN - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Occupant Restraint Controller Module C1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Occupant Restraint Controller Module C1 > Page 312 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 24 Way Air Bag Control Module: Diagrams Occupant Restraint Controller Module C1 (Body) 24 Way Connector - (BODY) 24 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER C1 - (BODY) 24 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 24 Way > Page 315 Air Bag Control Module: Diagrams Occupant Restraint Controller Module C2 (Body) 32 Way Connector - (BODY) 32 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER C2 - (BODY) 32 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 24 Way > Page 316 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description Air Bag Control Module: Description and Operation Occupant Restraint Controller - Description DESCRIPTION The Occupant Restraint Controller (ORC) (1) is secured with three nuts to three studs on a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel near the dash panel. The ORC is located beneath the console shifter housing forward of the transmission gearshift mechanism and center floor console in the passenger compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow (2) printed on the label (3) on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges (5) on the left front and rear corners and near the center of the right side. A molded plastic electrical connector receptacle (4) exits the rearward facing side of the ORC housing. This receptacle connects the ORC to the vehicle electrical system through two dedicated take outs and connectors from the instrument panel wire harness. The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with or without side supplemental restraints. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description > Page 319 Air Bag Control Module: Description and Operation Occupant Restraint Controller - Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC) contains the supplemental restraint system logic circuits and controls all of the Supplemental Restraint System (SRS) components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and for SRS diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ORC microprocessor continuously monitors all of the SRS electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTCs, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. The ORC receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Totally Integrated Power Module (TIPM), and a fused ignition switch output (run-start) circuit through a second fuse in the TIPM. The ORC receives ground through a ground circuit and take out of the instrument panel wire harness. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. Refer to the appropriate wiring information for additional details. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the SRS components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup SRS protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from two remote front impact sensors located on the back of the right and left vertical members of the radiator support near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. On vehicles equipped with optional side curtain airbags or seat airbags, the ORC also monitors inputs from an internal rollover sensor and four additional remote impact sensors located on the left and right inner B-pillars and C-pillars to control deployment of the side curtain airbag and seat airbag units. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a SRS component deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side curtain airbags or seat airbags feature a second safing sensor within the ORC to provide confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require SRS protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either side curtain and seat airbag unit. The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC or the electronic controls or communication between other modules and devices that provide features of the SRS. The most reliable, efficient, and accurate means to diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal Air Bag Control Module: Service and Repair Occupant Restraint Controller - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain or seat airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side curtain and seat airbags in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side curtain and seat airbags will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the SRS components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. NOTE: Several different Occupant Restraint Controllers (ORC) are available for this vehicle. For vehicles equipped with the optional side curtain or seat airbags the ORC contains a second bi-directional safing sensor. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center console shifter bezel and pod from the top of the floor panel transmission tunnel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Removal. 3. Lift, but do not remove, the jute covered panel (1) over the Occupant Restraint Controller (ORC) (2) between the dash panel and the gearshift mechanism as necessary to access the ORC connections and fasteners. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal > Page 322 4. Remove the three nuts (2) that secure the ORC (3) to the three studs (1) on the ORC mount welded onto the top of the floor panel transmission tunnel (5). 5. Unlatch and disconnect the two instrument panel wire harness connectors (4) from the ORC connector receptacles located on the rearward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm on each connector. 6. Remove the ORC from the ORC mount. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal > Page 323 Air Bag Control Module: Service and Repair Occupant Restraint Controller - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain or seat airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side curtain and seat airbags in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side curtain and seat airbags will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the SRS components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. NOTE: Several different Occupant Restraint Controllers (ORC) are available for this vehicle. For vehicles equipped with the optional side curtain or seat airbags the ORC contains a second bi-directional safing sensor. 1. Lift, but do not remove, the jute covered panel (1) over the Occupant Restraint Controller (ORC) (2) mount between the dash panel and the gearshift mechanism as necessary to reinstall the ORC, its connections and fasteners. CAUTION: Be certain that the jute covered panel over the ORC is restored to its original installed position following ORC service. Failure to do so may result in the setting of a false Diagnostic Trouble Code (DTC) and illumination of the airbag indicator. This cover protects the ORC from the gearshift selector cables vibrating against or striking the top of the ORC housing, which could be falsely interpreted as a vehicle impact pulse by the sensors within the ORC. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal > Page 324 2. Carefully position the Occupant Restraint Controller (ORC) (3) onto the three studs (1) of the ORC mount on the floor panel transmission tunnel (5). The bottom of the ORC housing is keyed. When the ORC is correctly positioned, the bottom of the housing will fit flush with the mount and the orientation arrow on the label on top of the housing will be pointed forward in the vehicle. 3. Reconnect the two instrument panel wire harness connectors (4) to the ORC connector receptacles located on the rearward facing side of the module. Be certain that the latches on the connectors are each fully engaged. 4. Install and tighten the three nuts (2) that secure the ORC to the studs of the ORC mount. Tighten the nuts to 9 Nm (80 in. lbs.). 5. Restore the jute covered panel to its proper position over the ORC between the dash panel and the gearshift mechanism. 6. Reinstall the center console shifter pod and bezel onto the top of the floor panel transmission tunnel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Installation. 7. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Restraint Systems/Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 330 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C1 (Instrument Panel) 4 Way Steering Mounted Controls Communication Module: Diagrams Steering Control Module C1 (Instrument Panel) 4 Way Connector C1 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C1 (Instrument Panel) 4 Way > Page 333 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C2 (Instrument Panel) 6 Way Connector C2 - (INSTRUMENT PANEL) 6 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C1 (Instrument Panel) 4 Way > Page 334 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C4 (Instrument Panel) 4 Way Connector C4 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation/Communication - Description. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 337 Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 338 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation/Communication - Description. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 339 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. SCCM 1. Place the front road wheels in the STRAIGHT-AHEAD position. 2. Disconnect and isolate the negative battery cable. 3. Remove steering wheel See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Removal. 4. Remove upper and lower steering column shrouds to gain access to the Steering Column Control Module (SCCM) (3) See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 5. Lock the clockspring rotor in the center position as follows: Insert a pin through the hole in the rotor at the 10 o'clock position. 6. Remove the three screws (1) to the SCCM. 7. Disconnect the electrical connectors (2) between the SCCM (1) and the instrument panel wiring harness at the base of the SCCM and remove from column. DISASSEMBLY NOTE: There is no need to disassemble the Steering Column Control Module (SCCM) if only removing the SCCM from the column. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 342 1. Remove the left multi-function switch stalk retaining screw (2). 2. Pull the left stalk out of the SCCM. 3. Disconnect the left stalk electrical connector. 4. Separate the left switch from the SCCM. 5. Remove the one right multi-function switch retaining screw. 6. Pull right switch out of SCCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 343 7. Disconnect the right switch electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 344 Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Installation INSTALLATION NOTE: If SCCM is already assembled and needs to be installed, bypass ASSEMBLY and proceed with SCCM 1. ASSEMBLY 1. Connect the right stalk electrical connector. 2. Slide the right stalk into the groove and install the one retaining screw. 3. Connect the left stalk switch electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 345 4. Install the left stalk switch retaining screw. SCCM 1. Position the SCCM (3) over the steering column shaft (2). 2. Install the three screws (1). 3. Connect the electrical connectors (2) to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged. 4. Install steering column shrouds See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. Be sure all wires are inside of shrouds. 5. Install steering wheel ensuring the flats on hub align with the clockspring See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Installation. Pull the airbag leads through the larger slot. Ensure leads do not get pinched under the steering wheel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 346 NOTE: There is a small wire harness in the steering wheel and it contains the horn circuits and speed control circuits. 6. Connect the speed control and horn wire connector into the clockspring. 7. Pull the grenade pin out of the clockspring. 8. Install the driver airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Installation WARNING: Do not connect the negative battery cable at this time. Perform the Air Bag System Test prior to connecting the negative battery cable See: Restraint Systems/Testing and Inspection . Failure to follow this warning may result in accidental air bag deployment and possible serious or fatal injury. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 352 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 353 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Tire Pressure Monitor Receiver / Transponder: Diagrams Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT FRONT (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way > Page 356 Tire Pressure Monitor Receiver / Transponder: Diagrams Left Rear Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT REAR (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way > Page 357 Tire Pressure Monitor Receiver / Transponder: Diagrams Right Rear Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-RIGHT REAR (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Description DESCRIPTION A transponder, sometimes referred to as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of a vehicle equipped with Premium TPM. These transponders are used to provide the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. On this vehicle, there is a transponder located in the left front, left rear, and right rear wheelhouse. There is not a transponder located in the right front wheelhouse. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description > Page 360 Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Operation OPERATION On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (The auto-locating process will start again only if the vehicle has been shut off for approximately 20 minutes or longer). Once the WCM has performed this to the three locations that have transponders, it uses the process-of-elimination theory to figure out the location of the fourth sensor ID. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Removal Front FRONT 1. Remove the wheelhouse splash shield at the transponder requiring service. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 2. Disconnect the wiring harness connector (2) at the transponder (1). 3. Remove the mounting nuts (3), then remove the transponder (1). Rear REAR 1. Remove the wheelhouse splash shield at the transponder requiring service. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 2. Disconnect the wiring harness connector (3) at the transponder (1). 3. Remove the mounting nuts (2), then remove the transponder (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 363 Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Installation Front FRONT 1. Position the transponder (1) and install the mounting nuts (3). 2. Connect the wiring harness connector (2) to the transponder (1). 3. Install the wheelhouse splash shield and all components removed to access it. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test. Rear REAR 1. Position the transponder (1) and install the mounting nuts (2). 2. Connect the wiring harness connector (3) to the transponder (1). 3. Install the rear wheelhouse splash shield and all components removed to access it. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Transmission Control Module C1 (CVT) (Body) 24 Way Control Module: Diagrams Transmission Control Module C1 (CVT) (Body) 24 Way Connector C1 (CVT) - (BODY) 24 WAY MODULE-TRANSMISSION CONTROL (CVT) - (BODY) 24 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Transmission Control Module C1 (CVT) (Body) 24 Way > Page 370 Control Module: Diagrams Transmission Control Module C2 (CVT) (Body) 24 Way Connector C2 (CVT) - (BODY) 24 WAY MODULE-TRANSMISSION CONTROL (CVT) - (BODY) 24 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation Control Module: Description and Operation Operation OPERATION Shift Control In order to select the gear ratio which can obtain the driving force in accordance with driver's intention and the vehicle condition, TCM monitors the driving conditions, such as the vehicle speed and the throttle position and selects the optimum gear ratio, and determines the gear change steps to the gear ratio. Then it sends the command to the stepping motor, and controls the flow-in/flow-out of line pressure to/from the primary pulley to determine the position of the moving-pulley and control the gear ratio. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 373 Selection of the gear ratio is set for every position separately. "Drive" Position Shifting is available over all the ranges of gear ratios from the lowest to the highest. When using the Manual Mode (Vehicles with the manual mode) When the manual mode switch is turned ON, the fixed changing gear line is set. By moving the switch to + side or - side, shift change is like a M/T and selects from a range of 6 pre-programmed gear ranges. By limiting the shift to the area nearest the low side of the gear ratio, a larger driving force and engine brake are secured. Downhill Engine Brake Control When a downhill condition is detected while the accelerator pedal is released, the engine brake will be increased by downshifting so as to limit acceleration of the vehicle. Also, if uphill is detected, acceleration performance is improved by limiting the shift area on the highest side of the gear ratio. Acceleration Control According to vehicle speed and a increase of accelerator pedal angle, driver's request for acceleration as well as driving conditions are measured. At the time of starting or acceleration while moving, this function improves in acceleration feeling by making the engine speed proportionate to the vehicle speed. Even at the time of slower acceleration, a shift map which can gain a larger driving force is chosen for compatibility of mileage with drivability. Line Pressure and Secondary Pressure Control Control of line pressure and secondary pressure with a high degree of accuracy has reduced friction and improved fuel economy. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 374 Normal Fluid Pressure Control The line pressure and the secondary pressure are optimized depending on driving conditions, on the basis of the throttle position, the engine speed, the primary pulley (input) revolution speed, the secondary pulley (output) revolution speed, the stop lamp SW signal, the PNP switch signal, the lock-up signal, the voltage, the target gear ratio, the fluid temperature, and the fluid pressure. Secondary Pressure Feedback Control When controlling the normal fluid pressure or the fluid pressure at the time of selection, the secondary pressure can be set more accurately by using the fluid pressure sensor to detect the secondary pressure and performing the feedback control. Lock-up Control The lock-up applied gear range has been expanded by locking up the torque converter at a lower vehicle speed than conventional A/T models. Selection Control When selecting between N (P) and D(R) position, the optimum operating pressure is set on the basis of the throttle position, the engine speed, and the secondary pulley (output) revolution speed to lessen the select shock. CAN Communication Real-time communications (signal exchanges) are maintained among the control units such as the CVT, C/U, ECM, combination meter etc. Each unit is controlled optimally depending on vehicle driving conditions while sharing information and in cooperating with the other control units. In CAN (Controller Area Network) communication, control units are connected with two communication lines (CAN-H line, CAN-L line) allowing a high rate of information to be transmitted by fewer wirings. Each control unit transmits/receives data but selectively reads required data only. Inputs and Outputs Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 375 Engine/CVT Integration Control (CAN Communication Control) In order to improve gearshift feeling and to perform controls such as prevention of engine slowdown, engine power control signals are intercommunicated between the engine ECM and the TCM, and real-time cooperative controls depending on vehicle driving conditions are performed. TCM sends information such as fast slowdown signals, lock-up signals, torque down request signals to ECM, while receiving information such as torque down permission/prohibition signals, lock-up permission/prohibition signals, throttle position from ECM. Fail-safe Function If an unexpected signal is sent from any sensor, switch, solenoid etc., this function controls the CVT to make driving as smooth as possible. Secondary Speed Sensor The shift pattern is changed in accordance with throttle position when an unexpected signal is sent from the output speed sensor (secondary speed sensor) to the TCM. The manual mode position or the sports mode position is inhibited, and the transaxle is put in "D". Primary Speed Sensor The shift pattern is changed in accordance with throttle position and secondary speed (vehicle speed) when an unexpected signal is sent from the primary speed sensor to the TCM. The manual mode function or the sports mode function is inhibited, and the transaxle is put in "D". PNP Switch If an unexpected signal is sent from the PNP switch to the TCM, the transaxle is put in "D". Fluid Temperature Sensor If an unexpected signal is sent from the fluid temperature sensor to the TCM, the gear ratio obtained immediately before receiving the unexpected signal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 376 is maintained and the gear ratio is controlled to keep engine speed under 5,000 rpm (approximately), depending on driving conditions. Secondary Pressure Sensor If an unexpected signal is sent from the secondary pressure sensor to the TCM, the secondary pressure feedback control is stopped and the offset value obtained immediately before the non-standard condition occurs is used to control line pressure. Line Pressure Solenoid If an unexpected condition of the solenoid is detected by the TCM, the line pressure solenoid is turned OFF to achieve the maximum fluid pressure. Secondary Pressure Solenoid If an unexpected condition of the secondary solenoid is detected by the TCM, the secondary pressure solenoid is turned OFF to achieve the maximum fluid pressure. Lock-up solenoid If an unexpected condition of the lock-up solenoid is detected by the TCM, the lock-up solenoid is turned OFF to cancel the lock-up. Stepping Motor If an unexpected condition of the stepping motor is detected by the TCM, the stepping motor coil phases "A" through "D" are all turned OFF to hold the gear ratio used immediately before the unexpected condition occurred. Lock-up/Selection Switching Solenoid If an unexpected condition of the solenoid is detected by the TCM, the lock-up/selection switching solenoid is turned OFF to cancel the lock-up. Backup Power Supply Transaxle assembly is protected by limiting the engine torque when the memory back-up power supply for controlling from the battery is not supplied to the TCM. Normal status is restored when turning the ignition switch OFF to ON after power is normally supplied TCM - 1. Shift control - 2. Line pressure control - 3. Selection control - 4. Lock-up control - 5. Engine/CVT integration control [CAN communication control] - 6. Self-diagnosis function - 7. Fail-safe function Primary Speed Sensor, Secondary Speed Sensor Primary Speed Sensor It is installed near the CVT fluid cooler in the transaxle case. It sends rotating speed of the primary pulley (input shaft) to the TCM as a pulse signal. Secondary Speed Sensor It is installed near the output gear part in the transaxle case. It sends rotating speed of the secondary pulley (output shaft) to the TCM as a pulse signal. TCM converts the pulse signal to vehicle speed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures Control Module: Procedures Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. TCM Initialization TRANSMISSION CONTROL MODULE INITIALIZATION NOTE: Refer to the following table when the Transmission Control Module (TCM) and/or transaxle has been replaced to determine if the TCM memory must be erased. INITIAL LEARN (BRAND-NEW MODULE, MEMORY ALREADY CLEAR) Battery must be connected. If the Totally Integrated Power Module (TIPM) is to be configured, configure the TIPM and then turn ignition key to OFF/LOCKED briefly, then back to RUN. The shifter must be in PARK or NEUTRAL, engine not running. 1. Turn the ignition key to RUN for 4 seconds to allow reading of new values. 2. Turn ignition key to OFF/LOCKED for 2 seconds to allow storing new values in EEROM. 3. Turn the ignition key to RUN, with scan tool clear DTCs. 4. Turn ignition key to OFF/LOCKED for 2 seconds. 5. After at least 7 seconds, read DTCs. 6. If DTCs resets See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Testing and Inspection RELEARN, AFTER REPLACING A TRANSAXLE 1. Turn ignition key to RUN. 2. Clear learning memory using the scan tool. 3. Turn the ignition key to OFF/LOCKED for 2 seconds. 4. Turn the ignition key to RUN Clear DTCs. 5. Turn the ignition key to OFF/LOCKED for 2 seconds. 6. Turn ignition key to RUN. 7. After at least 7 seconds, read DTCs. 8. If DTCs resets See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Testing and Inspection Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 379 Control Module: Removal and Replacement Removal REMOVAL 1. The TCM (2) is located between the brake pedal bracket (1) and the left kick panel (3). 2. Unplug the two electrical connectors (2) at the TCM. 3. Remove the two nuts (1) that hold the TCM to the bulkhead. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 380 4. Remove the TCM. Installation INSTALLATION 1. Install TCM mounting bracket holes (1) over the two studs on the bulkhead. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 381 2. Install the two nuts to mounting studs (1) on the bulkhead and tighten to 15 Nm (130 in. lbs.). 3. Plug in electrical connectors (2) to TCM (3). NOTE: If a new TCM is installed a learn procedure must be performed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 386 Control Module: Diagrams Connector (AWD) - (BODY) 16 WAY MODULE-ALL WHEEL DRIVE CONTROL (AWD) - (BODY) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations Integrated Accessory Switch Assembly: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations > Page 395 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations > Page 396 Integrated Accessory Switch Assembly: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY SWITCH-BANK - (INSTRUMENT PANEL) 8 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations > Page 397 Integrated Accessory Switch Assembly: Description and Operation DESCRIPTION There is an Accessory Switch Bank Module (ASBM) located in the instrument panel center stack just below the heater a/c control. Included in this switch bank are: - Electronic Stability Program (ESP)/Traction Control Switch (TCS) Off (if equipped) - See: Sensors and Switches - Brakes and Traction Control/Traction Control Switch/Description and Operation - Hazard Switch (all models) - See: Sensors and Switches - Lighting and Horns/Hazard Warning Switch/Description and Operation/Hazard Warning Switch - Description - Heated Seat Switch (if equipped) - See: Sensors and Switches - Body and Frame/Seat Heater Switch/Description and Operation/Heated Seat Switch - Description - Passenger Airbag Disabled Lamp (PADL) Indicator (if equipped with OCS) - See: Restraint Systems/Description and Operation/Restraints - Description. The BUX version of the ASBM will vary from the domestic a bit. Following are the various BUX switches: - Anti-Skid Control (ASC) (if equipped) - This is the same as the ESP/TCS off switch in the domestic version. - Hazard Switch (all models) - Heated Seat Switch (if equipped) - Headlamp Leveling Switch (if equipped) Each individual switch is not available for service replacement. If one or more switches are inoperative, the entire ASBM must be replaced See: Service and Repair/Instrument Cluster Switch Pod - Removal. To diagnose the ASBM switches, use a scan tool and the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Instrument Cluster Switch Pod Removal Integrated Accessory Switch Assembly: Service and Repair Instrument Cluster Switch Pod Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the screws to the Accessory Switch Bank Module (ASBM) (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Instrument Cluster Switch Pod Removal > Page 400 Integrated Accessory Switch Assembly: Service and Repair Instrument Cluster Switch Pod Installation INSTALLATION 1. Position the Accessory Switch Bank Module (ASBM) (4) in the center bezel. 2. Install the screws to the ASBM. 3. Install the instrument panel center bezel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way Remote Switch: Diagrams Left Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-LEFT - (STEERING WHEEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way > Page 406 Remote Switch: Diagrams Right Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-RIGHT - (STEERING WHEEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Remote Radio Switches Description Remote Switch: Description and Operation Remote Radio Switches - Description DESCRIPTION Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Remote Radio Switches Description > Page 409 Remote Switch: Description and Operation Remote Radio Switches - Operation OPERATION These switches are resistor multiplexed units that are hard-wired to the Cab Compartment Node (CCN) through the clockspring. The CCN sends the proper messages on the Controller Area Network (CAN) data bus network to the radio receiver. For diagnosis of the CCN or the CAN data bus, the use of a scan tool and the proper Diagnostic Procedures manual are recommended. For more information on the operation of the remote radio switch controls, refer to the owner's manual in the vehicle glove box. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 410 Remote Switch: Testing and Inspection REMOTE SWITCHES WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. Any diagnosis of the Audio system should begin with the use of the scan tool. For complete circuit diagrams, refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. See: Service and Repair/Remote Radio Switches - Removal. 3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test table REMOTE RADIO SWITCH TEST NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in driver's seat. 4. If the switch resistance checks OK, go to 5. If not OK, replace the faulty switch. 5. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity. If OK, go to 6. If not OK, repair the open circuit as required. 6. Unplug the connector from the Cab Compartment Node (CCN). Check for continuity between the radio control circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to 7. If not OK, repair the short circuit as required. 7. Check for continuity between the radio control circuit cavities of the remote radio switch wire harness connector and the CCN wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the CCN and the CAN data bus. If not OK, repair the open circuit as required. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches - Removal Remote Switch: Service and Repair Remote Radio Switches - Removal REMOVAL WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Removal. 3. Remove the steering wheel See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Removal. 4. Unplug the wire harness connector from the remote radio switch. 5. Remove steering wheel rear cover. 6. Remove the remote radio switch from the steering wheel by depressing tabs on each side of each switch. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in driver's seat. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches - Removal > Page 413 Remote Switch: Service and Repair Remote Radio Switches - Installation INSTALLATION WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Install remote radio switch to the steering wheel. 2. Install steering wheel rear cover. 3. Connect the wire harness to the remote radio switch. 4. Install the steering wheel See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Installation. 5. Install the driver side airbag See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Installation. 6. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection Power Door Lock Switch: Testing and Inspection DOOR LOCK SWITCH 1. Remove the switch. 2. Using an ohmmeter, refer to Door Lock Switch Test table to determine if switch resistance is correct in the Lock and Unlock switch positions. Refer to Wiring Diagrams for harness connector pin-outs. DOOR LOCK SWITCH TEST Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal Power Door Lock Switch: Service and Repair Power Lock Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Removal. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal > Page 424 Power Door Lock Switch: Service and Repair Power Lock Switch - Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Installation 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 428 Power Mirror Switch: Diagrams Connector (LHD) - (LEFT FRONT DOOR) 10 WAY SWITCH-MIRROR (LHD) - (LEFT FRONT DOOR) 10 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 429 Power Mirror Switch: Testing and Inspection POWER MIRROR SWITCH - LHD 1. Disconnect and isolate the battery negative cable. 2. Remove power mirror switch See: Service and Repair/Power Mirror Switch - Removal. 3. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Test table. 4. If test results are not obtained as shown in the Mirror Switch Test table, replace the switch. MIRROR SWITCH TEST TABLE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 430 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch - Removal Power Mirror Switch: Service and Repair Power Mirror Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Removal. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch - Removal > Page 433 Power Mirror Switch: Service and Repair Power Mirror Switch - Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Installation 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description Seat Heater Switch: Description and Operation Heated Seat Switch - Description DESCRIPTION The heated seat switches are located in the center stack (1) of the instrument panel. The switches are located on the outer edges of the accessory switch bank (2). If either of the switches is damaged or inoperative the complete accessory switch bank assembly must be replaced. When either of the heated seat switches are depressed a switch status message is sent to the Cab Compartment Node (CCN) or instrument cluster via the Local Interface Network (LIN) data bus. The CCN then sends a message via the LIN data bus to the heated seat module, signaling the module to energize the heating element for the selected seat. Amber Light Emitting Diodes (LEDs) in the top portion of each switch indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. The heated seat module sends the LED illumination message to the CNN via the LIN data bus. The CNN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. The LED indicator lamps in each heated seat switch cannot be repaired. If the LED lamps are inoperative or damaged, or the switch is inoperative or damaged the complete accessory switch bank assembly must be replaced. For Service information See: Sensors and Switches Accessories and Optional Equipment/Integrated Accessory Switch Assembly/Service and Repair/Instrument Cluster Switch Pod - Removal orSee: Sensors and Switches - Accessories and Optional Equipment/Integrated Accessory Switch Assembly/Service and Repair/Instrument Cluster Switch Pod - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description > Page 438 Seat Heater Switch: Description and Operation Heated Seat Switch - Operation OPERATION The heated seat switches are active any time the Local Interface Network (LIN) data bus is active. Depressing the heated seat switch provides a switch status message to the Cabin Compartment Node (CCN) via the LIN data bus. The CCN is responsible for supplying the LIN data bus message to the heated seat module, signaling the module to power the heated seat element of the selected seat and maintain the temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the CCN will go through the process again to change the temperature setting. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 439 Seat Heater Switch: Testing and Inspection HEATED SEAT SWITCH In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal Seat Heater Switch: Service and Repair Heated Seat Switch - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The heated seat switches are integral to the accessory switch bezel and cannot be serviced separately. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a work bench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the screws that secure the accessory switch bank (4) to the back of the center bezel and remove the accessory switch bank. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal > Page 442 Seat Heater Switch: Service and Repair Heated Seat Switch - Installation INSTALLATION NOTE: There are different instrument panel accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. 1. Position the accessory switch bank (4) onto the back of the instrument panel center bezel. 2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 1 Nm (8 in. lbs.). 3. Install the center bezel onto the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Reconnect the negative battery cable. 5. Verify heated seat system operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Sunroof Switch - Description Sunroof / Moonroof Switch: Description and Operation Sunroof Switch - Description DESCRIPTION The power sunroof switch (2) is a combination push-button and rocker switch module mounted in the Courtesy/Reading Lamp assembly (1). The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof express open (back of switch pushed and released) - Power sunroof closed (front of switch pushed) - Power sunroof express closed (front of switch pushed and released) - Power sunroof vent (switch center button pushed) The power sunroof switch cannot be repaired. If the individual components are damaged or inoperative the switch assembly must be replaced, See: Service and Repair/Sunroof Switch Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Sunroof Switch - Description > Page 447 Sunroof / Moonroof Switch: Description and Operation Sunroof Switch - Operation OPERATION The sunroof is electrically operated from two switches located in the headliner on the courtesy/reading lamp assembly. The power sunroof switch is hard wired to the sunroof motor/module assembly. The "VENT" switch is a push button type switch and opens the sunroof to the vent position only. The other switch "OPEN/CLOSED" is a rocker type switch for opening and closing the sunroof. Pressing and releasing the open button once, the sunroof will express open and the wind deflector will raise. If the button is pressed a second time the sunroof will stop in that position. Pressing and releasing the close button once will express close the sunroof. If the close button is pressed a second time during the express close operation the sunroof will stop in that position. The switch is grounded at one terminal and receives a 5 volt signal from the sunroof motor/module on the remaining three terminals. The switch pulls down the 5 volt reference voltage from the module signaling it to perform the desired function. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Page 448 Sunroof / Moonroof Switch: Testing and Inspection SUNROOF SWITCH For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the power sunroof switch, See: Service and Repair/Sunroof Switch - Removal. 2. Disconnect the power sunroof switch wire harness connector. 3. With the ignition key in the "RUN" position check for 5 volts on the "OPEN", "CLOSE" and "VENT" circuits of the sunroof switch harness connector. If OK, go to 4. If not OK, inspect the wiring harness and connectors between the motor/module and switch for damage and repair as necessary. 4. With the ignition key in the "OFF" position check for continuity between the ground circuit of the sunroof switch harness connector and a known good ground. Continuity should be present. If OK, go to 5. If not OK, inspect the wiring harness and connector and repair the ground circuit as necessary. 5. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage and repair as necessary. If not OK, replace the power sunroof switch, See: Service and Repair/Sunroof Switch Removal. POWER SUNROOF SWITCH CONTINUITY TABLE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch - Removal Sunroof / Moonroof Switch: Service and Repair Sunroof Switch - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the courtesy/reading lamp lens (5). Insert a suitable flat bladed tool into the slot (6) in the courtesy/reading lamp assembly (2). Pivot the lens down and to the left to release the holding tab (4). 3. Using a suitable flat bladed tool, release the mounting tabs (5) from the sides of the sunroof control switch (4) and pull the switch down from the courtesy/reading lamp assembly (2). 4. Disconnect the electrical connector (3) from the sunroof control switch (4). 5. Remove the switch from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch - Removal > Page 451 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch - Installation INSTALLATION 1. Position the sunroof control switch (4) into the vehicle. 2. Connect the sunroof control switch electrical connector (3). 3. Insert the sunroof control switch (4) into the courtesy/reading lamp assembly (2). Push up on the switch until it is securely held in place by the mounting tabs (5). 4. Insert the mounting tab (4) on the lamp lens (5) into the right side of the lamp assembly and pivot the lens up until it snaps securely in place. 5. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 456 Brake Fluid Level Sensor/Switch: Diagrams Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-BRAKE FLUID LEVEL - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 457 Brake Fluid Level Sensor/Switch: Description and Operation DESCRIPTION The brake fluid level switch (2) is mounted through the center of the fluid reservoir (1). The switch can be serviced separately from the master cylinder fluid reservoir. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Brake Fluid Level Switch - Removal Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Switch - Removal REMOVAL NOTE: Before proceeding, See: Brakes and Traction Control/Service Precautions/Technician Safety Information See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings . 1. Remove the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. 2. Push together the retaining tabs (1) holding the brake fluid level switch in place in the brake fluid reservoir (2). 3. Pull the brake fluid level switch out the right side of the reservoir. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Brake Fluid Level Switch - Removal > Page 460 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Switch - Installation INSTALLATION 1. Align the brake fluid level switch with its mounting hole on the right side of the master cylinder brake fluid reservoir. Push the switch into the fluid reservoir until the switch retaining tabs (1) are expanded on the opposite side of the reservoir (2), locking it in place. 2. Connect the wiring harness connector (1) to the switch (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 464 Lateral Accelerometer: Diagrams Connector (ESP) - (BODY) 6 WAY SENSOR-DYNAMICS (ESP) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 465 Lateral Accelerometer: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (2). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal Lateral Accelerometer: Service and Repair Dynamics Sensor - Removal REMOVAL NOTE: The Occupancy Restraint Module (ORC) (4) is directly behind the vehicle dynamics sensor (2). Care must be taken while working near the ORC to avoid jostling or bumping the module. 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the shifter housing. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Housing - Removal 3. Position the carpeting out of the way so that the dynamics sensor is accessible. 4. Remove the two nuts (1) mounting the dynamics sensor to the floor pan tunnel. 5. Disconnect the wiring harness connector (3) at the dynamics sensor (2). 6. Remove the dynamics sensor (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 468 Lateral Accelerometer: Service and Repair Dynamics Sensor - Installation INSTALLATION NOTE: The Occupancy Restraint Module (ORC) (4) is directly behind the vehicle dynamics sensor (2). Care must be taken while working near the ORC to avoid jostling or bumping the module. 1. Connect the wiring harness connector (3) to the dynamics sensor (2). 2. Install the dynamics sensor (2) over the studs mounted to the floor pan tunnel. 3. Install the two mounting nuts (1). Tighten the nuts to 9 Nm (80 in. lbs.). 4. Move carpeting back into original location. 5. Install the shifter housing See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Housing - Installation 6. Connect the battery negative cable to the battery post. It is important that this be performed properly See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection 7. Perform the Verification Test and clear any faults See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 472 Parking Brake Warning Switch: Diagrams Connector - (INSTRUMENT PANEL) 1 WAY SWITCH-PARKING BRAKE - (INSTRUMENT PANEL) 1 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 476 Steering Angle Sensor: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SENSOR-STEERING ANGLE - (INSTRUMENT PANEL) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Description and Operation Traction Control Switch: Description and Operation DESCRIPTION The ESP Off Switch is part of the accessory switch bank module located in the center bezel on the instrument panel above the transmission gear shifter. The ESP Off switch turns the Electronic Stability Program off whenever the switch is depressed. Depressing the switch a second time turns the ESP(R) back on. The switch resets itself each time the ignition is cycled. When the ESP Off switch is depressed and released, turning ESP(R) off, it does not completely turn the system off. The ESP(R) system reduces torque management to a lesser amount, but ESP(R) function can still occur if the system perceives the need. The ESP Off switch is serviced as part of the accessory switch bank. There are different accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Electronic Stability Program (ESP) Switch - Removal Traction Control Switch: Service and Repair Electronic Stability Program (ESP) Switch - Removal REMOVAL NOTE: The ESP Off switch is integral to the accessory switch bank and cannot be serviced separately. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a work bench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the screws that secure the accessory switch bank to the back of the center bezel and remove the accessory switch bank. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Electronic Stability Program (ESP) Switch - Removal > Page 482 Traction Control Switch: Service and Repair Electronic Stability Program (ESP) Switch - Installation INSTALLATION NOTE: The ESP Off switch is serviced as part of the accessory switch bank. NOTE: There are different instrument panel accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. 1. Position the accessory switch bank onto the back of the instrument panel center bezel. 2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the center bezel onto the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Reconnect the negative battery cable. 5. Perform the ABS Verification Test and make sure the ESP Off switch operates properly. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test 6. Verify proper operation of all components controlled by the switch bank. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front ABS Wheel Speed Sensor Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front ABS Wheel Speed Sensor > Page 487 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front ABS Wheel Speed Sensor > Page 488 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front ABS Wheel Speed Sensor > Page 489 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way Wheel Speed Sensor: Diagrams Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT FRONT - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 492 Wheel Speed Sensor: Diagrams Left Front ABS Wheel Speed Sensor (Sensor Side) (Engine Compartment) 2 Way Connector (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT FRONT (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 493 Wheel Speed Sensor: Diagrams Left Rear ABS Wheel Speed Sensor (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT REAR - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 494 Wheel Speed Sensor: Diagrams Left Rear ABS Wheel Speed Sensor (Sensor Side) (Body) 2 Way Connector (SENSOR SIDE) - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT REAR (SENSOR SIDE) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 495 Wheel Speed Sensor: Diagrams Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT FRONT - (ENGINE COMPARTMENT) 2 WAY Left Front ABS Wheel Speed Sensor (Sensor Side) (Engine Compartment) 2 Way Connector (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT FRONT (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 496 Left Rear ABS Wheel Speed Sensor (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT REAR - (BODY) 2 WAY Left Rear ABS Wheel Speed Sensor (Sensor Side) (Body) 2 Way Connector (SENSOR SIDE) - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT REAR (SENSOR SIDE) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 497 Right Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT FRONT - (ENGINE COMPARTMENT) 2 WAY Right Front ABS Wheel Speed Sensor (Sensor Side) (Engine Compartment) 2 Way Connector (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT FRONT (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 498 Right Rear ABS Wheel Speed Sensor (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT REAR - (BODY) 2 WAY Right Rear ABS Wheel Speed Sensor (Sensor Side) (Body) 2 Way Connector (SENSOR SIDE) - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT REAR (SENSOR SIDE) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 499 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description Wheel Speed Sensor: Description and Operation Wheel Speed Sensor - Description Front DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magneto-resistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. A front wheel speed sensor (3) is attached to a mounting boss on each front knuckle (4). The encoder is an integral part of the hub and bearing. WSS air gaps are not adjustable. Rear DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magnetoresistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. The rear wheel speed sensor head (3) is mounted to the rear of the hub and bearing by a screw. The encoder is integral to the hub and bearing assembly. The encoder is are serviced as part of the rear hub and bearing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description > Page 502 The WSS air gaps are not adjustable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description > Page 503 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor - Operation Front OPERATION The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Rear OPERATION The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Removal Front REMOVAL NOTE: Before proceeding, See: Brakes and Traction Control/Service Precautions/Technician Safety Information See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings . 1. Open the hood. 2. Disconnect the wheel speed sensor cable connector (2) from the wiring harness connector (3) on top of the frame rail (1) to the inside of the strut tower. 3. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 4. Remove the grommet (1) from the hole in the body (7) and pull the wheel speed sensor cable out of the hole. 5. Remove the speed sensor cable routing clip (2) from the outside frame rail (6). 6. Remove the screw fastening the cable routing clamp (3) to the outside frame rail (6). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 506 7. Remove the screw (1) securing the wheel speed sensor routing bracket (2) to the brake flex hose bracket (5). 8. Remove the mounting screw (2) fastening the wheel speed sensor head (3) to the knuckle (4). Pull the sensor head out of the knuckle. NOTE: In the following step, the routing clip can be easily removed without damaging it by rotating it (with entire sensor) counterclockwise. 9. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (4). Remove the sensor from the vehicle. Rear REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 507 NOTE: Before proceeding, See: Brakes and Traction Control/Service Precautions/Technician Safety Information See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings . 1. Remove the cargo floor cover. 2. Remove the rear floor pan silencer (1). 3. If equipped, remove the nuts mounting the satellite receiver (1) or amplifier (2) to rear floor pan. Move the component aside to allow access to the wheel speed sensor wiring connector through the opening in bottom of the quarter trim panel. 4. Through the opening in the bottom of the quarter trim panel, disconnect the wheel speed sensor cable connector (2) at the body wiring harness connector (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 508 5. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair. 6. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly (1). 7. Remove the grommet (2) from the hole in the body (1) and pull the wheel speed sensor cable out through the hole. 8. Remove the speed sensor cable routing clip (3) from the outside frame rail (4). 9. Remove the screw (1) fastening the cable routing clamp (3) to the rear suspension crossmember (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 509 10. Remove the speed sensor cable routing clip (1) from the trailing link (2). 11. Remove the screw (4) fastening the cable routing clamp to the trailing link. 12. Remove the screw (1) fastening the wheel speed sensor head (3) in the rear of the hub and bearing (2). Remove the sensor from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 510 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Installation Front INSTALLATION CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. 1. Install the wheel speed sensor head (3) into the knuckle (4). Install the mounting screw (2) and tighten it to 12 Nm (106 in. lbs.). 2. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (4). 3. Position the wheel speed sensor routing bracket (2) on the brake flex hose bracket (5) and install the mounting screw (1). Tighten the mounting screw to 18 Nm (13 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 511 4. Position the wheel speed sensor cable routing clamp (4) on the outside frame rail (6) and install the mounting screw (3). Tighten the mounting screw to 18 Nm (13 ft. lbs.). 5. Install the speed sensor cable routing clip (2) on the outside frame rail (6). 6. Insert the wheel speed sensor cable through the hole in the body (7) and install the grommet (1) in the hole. 7. Lower the vehicle. 8. Connect the wheel speed sensor cable connector (2) to the wiring harness connector (3) on top of the frame rail (1). 9. Perform the Diagnostic Verification Test and clear any faults. See: Brakes and Traction Control/Brake Bleeding/Service and Repair Rear INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 512 1. Install the wheel speed sensor head (3) into the rear of the hub and bearing (2). 2. Install the wheel speed sensor head mounting screw (1). Tighten the screw to 10 Nm (89 in. lbs.). 3. Position the wheel speed sensor (3) on the trailing link (2) and install the screw (4) securing it in place. Tighten the mounting screw to 18 Nm (13 ft. lbs.). 4. Position the wheel speed sensor (3) and install the routing clip (1) fastening the sensor to the trailing link (2). 5. Position the wheel speed sensor cable routing clamp (3) on the rear suspension crossmember (4) and install the mounting screw (1). Tighten the mounting screw to 18 Nm (13 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 513 6. Install the speed sensor cable routing clip (3) on the outside frame rail (4). NOTE: When inserting the wheel speed sensor cable through the hole in the body, route the cable toward the shock tower to make it easier to grasp the cable to connect it to the body wiring harness connector in a later step. 7. Insert the wheel speed sensor cable (5) through the hole in the body (1) and install the grommet (2) in the hole. 8. Install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 514 10. Through the opening in the bottom of the quarter trim panel, connect the wheel speed sensor cable connector (2) at the body wiring harness connector (3). 11. If equipped, install the satellite receiver (1) or amplifier (2) to rear floor pan. 12. Install the rear floor pan silencer (1). 13. Install the cargo floor cover. 14. Perform the Diagnostic Verification Test and clear any faults. See: Brakes and Traction Control/Brake Bleeding/Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 518 Yaw Rate Sensor: Diagrams Connector (ESP) - (BODY) 6 WAY SENSOR-DYNAMICS (ESP) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 519 Yaw Rate Sensor: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (2). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal Yaw Rate Sensor: Service and Repair Dynamics Sensor - Removal REMOVAL NOTE: The Occupancy Restraint Module (ORC) (4) is directly behind the vehicle dynamics sensor (2). Care must be taken while working near the ORC to avoid jostling or bumping the module. 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the shifter housing. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Housing - Removal 3. Position the carpeting out of the way so that the dynamics sensor is accessible. 4. Remove the two nuts (1) mounting the dynamics sensor to the floor pan tunnel. 5. Disconnect the wiring harness connector (3) at the dynamics sensor (2). 6. Remove the dynamics sensor (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 522 Yaw Rate Sensor: Service and Repair Dynamics Sensor - Installation INSTALLATION NOTE: The Occupancy Restraint Module (ORC) (4) is directly behind the vehicle dynamics sensor (2). Care must be taken while working near the ORC to avoid jostling or bumping the module. 1. Connect the wiring harness connector (3) to the dynamics sensor (2). 2. Install the dynamics sensor (2) over the studs mounted to the floor pan tunnel. 3. Install the two mounting nuts (1). Tighten the nuts to 9 Nm (80 in. lbs.). 4. Move carpeting back into original location. 5. Install the shifter housing See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Housing - Installation 6. Connect the battery negative cable to the battery post. It is important that this be performed properly See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection 7. Perform the Verification Test and clear any faults See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 > Page 529 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor 2 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 > Page 530 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way > Page 533 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 2 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 2 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 534 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. ENGINE COOLANT TEMPERATURE SENSOR WIRING OR CONNECTORS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 535 NOTE: Diagnose and repair any ECT circuit DTCs before proceeding with this test. NOTE: Allow the engine to cool to ambient temperature before proceeding. 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature sensor(s) and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Turn the ignition on. 5. Monitor the scan tool data relative to the sensor(s) and wiggle test the wiring and connectors. 6. Look for the data to change or for a DTC to set during the wiggle test. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. ENGINE COOLANT LEVEL AND CONDITION WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Check the engine coolant level and the condition of the engine coolant. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. THERMOSTAT WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Using the appropriate service information, determine the proper opening temperature of the thermostat. 2. With the scan tool, read the Engine Coolant Temperature Sensor value for each sensor. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 3. Monitor the sensor values on the scan tool. 4. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: Each thermostat should open at the temperature specified. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 536 Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. ENGINE COOLANT TEMPERATURE SENSOR NOTE: Allow the engine to cool to ambient temperature before proceeding. WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. With the scan tool, read the Engine Coolant Temperature Sensor value for each sensor. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 2. Monitor each sensor value on the scan tool and the actual coolant temperature with a thermometer. 3. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The sensor value transition should be smooth as the engine reaches operating temperature. The thermometer reading and the coolant temperature values on the scan tool should remain relatively close. Were any problems found? Yes - Go to 5. No - Test complete. 5. ECT SIGNAL CIRCUIT HIGH RESISTANCE NOTE: Perform this procedure for the sensor where erratic sensor values were detected in the previous test step. 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the ECT Signal circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 No - Repair the ECT Signal circuit for excessive resistance. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 537 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the Sensor Ground circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. ENGINE COOLANT TEMPERATURE SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Engine Coolant Temperature Sensor. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 542 Cruise Control Switch: Diagrams Connector - (STEERING WHEEL) 3 WAY SWITCH-SPEED CONTROL - (STEERING WHEEL) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal Cruise Control Switch: Service and Repair Speed Control Switch - Removal REMOVAL WARNING: Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. This will disable the front airbag system. Failure to disconnect the battery could result in accidental front airbag module deployment and possible personal injury.Do not place a non-deployed airbag face down on a hard surface as the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. 1. Disconnect and isolate the negative battery cable before beginning steering wheel removal. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. 2. Turn off ignition. 3. Remove the driver's side airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Removal. 4. Disconnect electrical connector (1) from horn switch (2). 5. Remove mounting screws (3) and horn switch (2) from steering wheel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal > Page 545 6. Disconnect electrical connector (1) from speed control switch (3). 7. Remove screws (4) from speed control switch (3). 8. Remove speed control switch (3) from steering wheel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal > Page 546 Cruise Control Switch: Service and Repair Speed Control Switch - Installation INSTALLATION 1. Install speed control switch (3) onto the locating pin (2) in the steering wheel. Make sure rubber seal is in place around switch. 2. Install speed control switch mounting screws (4) and tighten screws to 1.6 Nm (15 ins. lbs.). 3. Connect electrical connector (1) to speed control switch (3). 4. Install horn switch (2) to steering wheel. 5. Connect electrical connector (1) to horn switch (2). 6. Install horn switch mounting screws (3) and tighten screws to 8 Nm (71 ins. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal > Page 547 7. Install driver's side airbag See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Installation. 8. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). 9. Verify vehicle and system operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 552 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 553 Oil Pressure Sender: Diagrams Connector - (POWERTRAIN) 2 WAY SWITCH-ENGINE OIL PRESSURE - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Description and Operation > Oil Pressure Switch - Description Oil Pressure Switch (For Fuel Pump): Description and Operation Oil Pressure Switch - Description DESCRIPTION The oil pressure switch is located on the left front side of the engine block. The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Description and Operation > Oil Pressure Switch - Description > Page 558 Oil Pressure Switch (For Fuel Pump): Description and Operation Oil Pressure Switch - Operation OPERATION The oil pressure switch is normally "Closed." The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig. The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Raise and support the vehicle See: Maintenance/Vehicle Lifting/Service and Repair 3. Remove the splash shield from the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 4. Remove the accessory drive belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal 5. Remove the three bolts (2) and reposition the A/C compressor (1). 6. Disconnect the oil pressure switch electrical connector. 7. Remove the oil pressure switch using oil pressure socket C-4597 (1) or equivalent. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal > Page 561 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Installation INSTALLATION NOTE: If the oil pressure switch is removed, it must be replaced with a new switch. CAUTION: The oil pressure switch has tapered threads, over tightening could crack the engine block. 1. Install the oil pressure switch using oil pressure socket C-4597 (1) or equivalent. Tighten switch to 8 Nm (71 in. lbs.). 2. Connect the oil pressure switch electrical connector. 3. Position the A/C compressor (1) and install three mounting bolts (2). Tighten bolts to 25 Nm (18 ft. lbs.). 4. Install the accessory drive belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation 5. Install the splash shield to the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 6. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 565 Oil Temperature Sensor/Switch: Diagrams Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-OIL TEMPERATURE (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Oil Temperature Sensor - Removal Oil Temperature Sensor/Switch: Service and Repair Oil Temperature Sensor - Removal REMOVAL 1. Disconnect oil temperature sensor (1) electrical connector. 2. Remove sensor (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Oil Temperature Sensor - Removal > Page 568 Oil Temperature Sensor/Switch: Service and Repair Oil Temperature Sensor - Installation INSTALLATION 1. If re-using the oil temperature sensor, coat the threads with Mopar(R) thread sealant. 2. Install oil temperature sensor (1). Tighten to 18 Nm (160 in. lbs.). 3. Connect electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Sensor: Service and Repair Removal EXHAUST PRESSURE SENSOR 1. Disconnect and isolate negative battery cable. 2. Remove electrical connector at pressure differential sensor (2). 3. Remove upstream exhaust pressure tube (4) from catalytic converter 4. Remove downstream pressure tube (6) from catalytic converter. 5. Remove pressure differential sensor mounting bolt. 6. Remove pressure differential sensor (2) and tubing (7) from vehicle. 7. Remove tubing (7) from pressure differential sensor (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal > Page 574 Exhaust Pressure Sensor: Service and Repair Installation EXHAUST PRESSURE SENSOR 1. Install tubing (7) on pressure differential sensor (2). 2. Position pressure differential sensor (2) and tubing (7). 3. Install pressure differential sensor mounting bolt (3). Tighten to 10 Nm (89 in. lbs.). 4. Install downstream pressure tube (6) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.). 5. Install upstream pressure tube (4) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.) 6. Position electrical connector (1) into bracket. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Remove engine cover. 2. Disconnect and isolate negative batter cable. 3. Disconnect upstream DPF temperature sensor electrical connector. 4. Remove upstream DPF temperature sensor. 5. Disconnect downstream DPF temperature sensor electrical connector. 6. Remove downstream DPF temperature sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 579 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Position DPF downstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 2. Connect downstream temperature sensor electrical connector. 3. Position DPF upstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 4. Connect upstream temperature sensor electrical connector. 5. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 584 Ambient Temperature Sensor / Switch HVAC: Diagrams Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-AMBIENT AIR TEMPERATURE - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 588 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 589 Evaporator Temperature Sensor / Switch: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SENSOR-EVAPORATOR TEMPERATURE - (INSTRUMENT PANEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Evaporator Temperature Sensor - Description Evaporator Temperature Sensor / Switch: Description and Operation Evaporator Temperature Sensor - Description DESCRIPTION The evaporator temperature sensor measures the temperature of the conditioned air downstream of the A/C evaporator. The evaporator temperature sensor is an electrical thermistor (1) mounted on the end of a molded plastic housing (2) that is inserted into the driver side of the HVAC housing near the coldest point of the A/C evaporator. The evaporator temperature sensor is retained in the HVAC housing by two integral retaining tabs (3) and is connected to the vehicle electrical system by use of a wire lead and connector (4) with two terminals. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Evaporator Temperature Sensor - Description > Page 592 Evaporator Temperature Sensor / Switch: Description and Operation Evaporator Temperature Sensor - Operation OPERATION The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an input signal to the Cabin Compartment Node (CCN). The CCN uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the CCN through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The CCN uses the monitored voltage reading as an indication of evaporator temperature. The CCN is programmed to respond to this input by requesting the Powertrain Control Module (PCM) or the Engine Control Module (ECM) (depending on engine application) to cycle the A/C clutch off and on as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing See: Heating and Air Conditioning/Compressor HVAC/Description and Operation/A/C Compressor - Operation. The evaporator temperature sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The evaporator temperature sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Evaporator Temperature Sensor - Removal Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Illustration shown with air distribution housing removed for clarity. NOTE: It is not necessary to remove and disassemble the HVAC housing to service the evaporator temperature sensor. The evaporator temperature sensor can be removed for service from underneath the instrument panel. 1. Disconnect and isolate the negative battery cable. 2. Reach up under the driver side of the instrument panel and disconnect the electrical connector for the evaporator temperature sensor (1) from the instrument panel wire harness. 3. Using needle nose pliers, disengage the two retaining tabs (3) that secure the evaporator temperature sensor to the HVAC housing (2) by carefully pulling the sensor straight out of the side of the HVAC housing. 4. Route the electrical connector and wire lead of the evaporator temperature sensor out from under the heater core tubes and remove the sensor from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Evaporator Temperature Sensor - Removal > Page 595 Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Installation INSTALLATION NOTE: Illustration shown with air distribution housing removed for clarity. 1. Route the electrical connector and wire lead of the evaporator temperature sensor (1) under the heater core tubes located on the driver side of the HVAC housing (2). 2. Install the evaporator temperature sensor into the driver side of the HVAC housing. Make sure the retaining tabs (3) are fully engaged to the housing. 3. Connect the electrical connector for the evaporator temperature sensor to the instrument panel wire harness. 4. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 599 Refrigerant Pressure Sensor / Switch: Diagrams Connector - (ENGINE COMPARTMENT) 4 WAY TRANSDUCER-A/C PRESSURE - (ENGINE COMPARTMENT) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer - Description Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Transducer Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer - Description > Page 602 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Transducer Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line. The internal resistance of the A/C pressure transducer changes in response to the pressures it monitors. The Totally Integrated Power Module (TIPM) provides a five volt reference signal and a sensor ground to the A/C pressure transducer. The TIPM then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure and sends a message to the Powertrain Control Module (PCM) or Engine Control Module (ECM) (depending on engine application) over the Controller Area Network (CAN) C BUS. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the swash plate within the A/C compressor and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM adjusts the swash plate to nearly a zero degree angle (low compressor displacement) when high side pressure rises above 3130 kPa (454 psi) and readjusts the swash plate to a greater angle (higher compressor displacement) when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer also reduces the swash plate angle if the high side pressure drops below 200 kPa (29 psi) and will increase the swash plate angle when the high side pressure rises above 234 - 262 kPa (34 - 38 psi). When the refrigerant pressure rises above 1655 kPa (240 psi) the PCM will actuate the cooling fan. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Transducer - Removal Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Transducer - Removal REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. NOTE: Typical A/C pressure transducer shown. 1. Disconnect and isolate the negative battery cable. 2. Carefully pull the top of the fascia forward to gain access to the A/C pressure transducer (2) See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Removal. 3. Reach down through the opening between the A/C condenser and the front fascia and disconnect the wire harness connector (1) from the A/C pressure transducer located on the A/C discharge line (3). 4. Remove the A/C pressure transducer from the A/C discharge line and remove and discard the O-ring seal (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Transducer - Removal > Page 605 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Transducer - Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. NOTE: Typical A/C pressure transducer shown. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the A/C discharge line (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reinstall the top of the front fascia See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Installation. 5. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation Fuel Gauge Sender: Customer Interest Instruments - Fuel Gauge Fluctuation NUMBER: 08-024-10 GROUP: Electrical DATE: September 22, 2010 SUBJECT: Fuel Gauge Fluctuation OVERVIEW: This Bulletin involves replacing the fuel sending unit, clocking the fuel module and installing a fuel jumper hose. MODELS: 2007 - 2010 (PM) Caliber (FWD Only) 2007 - 2010 (MK) Compass / Patriot (FWD Only) SYMPTOM/CONDITION: The customer may complain that the fuel gauge is not accurate or fluctuates at 3/4 of a tank or above. DIAGNOSIS: Some customers may experience the condition described above. Preform the repair as described below. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Removal > Front Wheel Drive Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 615 NOTE: Mark the sending unit at the 4:00 position with 12:00 pointing to the rear of the vehicle. 2. Remove the fuel pump sending unit from the Pump module. 3. Install New Sender to the Fuel Pump Module. 4. Install Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Installation > Front Wheel Drive NOTE: Clock the Fuel Module to the 2:00 position Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 616 5. Install the jumper hose kit 6. Re-Connect battery 7. Start vehicle and check for leaks 8. Re-install Fuel Pump Cover 9. Re-install padding and rear seat bottom 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation Fuel Gauge Sender: All Technical Service Bulletins Instruments - Fuel Gauge Fluctuation NUMBER: 08-024-10 GROUP: Electrical DATE: September 22, 2010 SUBJECT: Fuel Gauge Fluctuation OVERVIEW: This Bulletin involves replacing the fuel sending unit, clocking the fuel module and installing a fuel jumper hose. MODELS: 2007 - 2010 (PM) Caliber (FWD Only) 2007 - 2010 (MK) Compass / Patriot (FWD Only) SYMPTOM/CONDITION: The customer may complain that the fuel gauge is not accurate or fluctuates at 3/4 of a tank or above. DIAGNOSIS: Some customers may experience the condition described above. Preform the repair as described below. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Removal > Front Wheel Drive Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 622 NOTE: Mark the sending unit at the 4:00 position with 12:00 pointing to the rear of the vehicle. 2. Remove the fuel pump sending unit from the Pump module. 3. Install New Sender to the Fuel Pump Module. 4. Install Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Installation > Front Wheel Drive NOTE: Clock the Fuel Module to the 2:00 position Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 623 5. Install the jumper hose kit 6. Re-Connect battery 7. Start vehicle and check for leaks 8. Re-install Fuel Pump Cover 9. Re-install padding and rear seat bottom 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module (AWD) Fuel Gauge Sender: Locations Fuel Pump Module (AWD) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module (AWD) > Page 626 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module (AWD) > Page 627 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way Fuel Gauge Sender: Diagrams Fuel Pump Module (FWD) (Body) 4 Way Connector (FWD) - (BODY) 4 WAY MODULE-FUEL PUMP (FWD) - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way > Page 630 Fuel Gauge Sender: Diagrams Fuel Pump Module C1 (AWD) (Body) 5 Way Connector C1 (AWD) - (BODY) 5 WAY MODULE-FUEL PUMP (AWD) - (BODY) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way > Page 631 Fuel Gauge Sender: Diagrams Fuel Pump Module C2 (AWD) (Body) 2 Way Connector C2 (AWD) - (BODY) 2 WAY MODULE-FUEL PUMP (AWD) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Gauge Sender: Description and Operation Fuel Pump Module - Description DESCRIPTION - FUEL PUMP MODULE The fuel pump module is located on the top left side of the fuel tank. The fuel pump module contains the following components: - Mounting flange - Electric fuel pump - Fuel pump reservoir - Inlet strainer - Fuel pressure regulator - Fuel level sending unit - Fuel filter The fuel level sending unit (3) is the only serviceable component of the fuel pump module. If the electric fuel pump, fuel pressure regulator or fuel filter requires service, the fuel pump module must be replaced as an assembly. DESCRIPTION The fuel pump module is installed in the top of the fuel tank. The fuel pump module contains the following: - Electric fuel pump - Fuel pump reservoir Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description > Page 634 - Inlet strainer - Fuel pressure regulator - Fuel gauge sending unit - Fuel supply line connection - Fuel Filter NOTE: The fuel level sending unit is the only serviceable item. If the fuel pump, fuel pressure regulator or fuel filters need service, replace the fuel pump module as an assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description > Page 635 Fuel Gauge Sender: Description and Operation Fuel Pump Module - Operation OPERATION - FUEL PUMP MODULE An electric fuel pump is located within the fuel pump module. The electric fuel pump is a positive displacement, immersible pump with a permanent magnet electric motor capable of creating 860 kPa (125 psi) of operating pressure. The fuel pressure regulator limits fuel pressure to 400 kPa (58 psi). The fuel gauge is controlled by the instrument cluster circuit board based upon cluster programming and a hard wired input received by the cluster from the fuel level sending unit on the module in the fuel tank. The instrument cluster continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. This information is available to other vehicle control modules via the Controller Area Network (CAN) data bus. Fuel gauge diagnosis is conducted as part ofthe instrument cluster circuitry. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Gauge Sender: Service and Repair Fuel Pump Module - Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. 1. Perform Fuel System Pressure Release procedure. See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose. 3. Remove the negative battery cable. 4. Remove the rear seat cushion. 5. Rear seat cushion loose. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 638 6. Remove plastic cover. 7. Clean top of tank to remove loose dirt and debris. 8. Use special tool #9340 to remove left side module lock ring. 9. Note the fuel pump location on the top of the fuel tank. NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 639 10. Pull module up out of fuel tank, make sure that you do not spill fuel inside of vehicle. 11. Drain fuel from fuel pump module. Do not spill fuel in interior of vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 640 Fuel Gauge Sender: Service and Repair Fuel Pump Module - Installation INSTALLATION NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. 1. Wipe seal area of tank clean. Place a new seal between the tank threads and the pump module opening. 2. Install module. 3. Position fuel pump module in tank. Make sure the alignment tab lines up on the fuel tank and pump module for Gas or Diesel fuel tanks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 641 4. While holding the pump module in position, install lock ring and use special tool Spanner Wrench #9340 to tighten lock ring. 5. Install plastic cover. 6. Install rear cushion. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 642 7. Install the negative battery cable. 8. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. 9. Fill fuel tank with clean fuel. Use the Scan Tool to pressurize the system and check for leaks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor - Description Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Description DESCRIPTION The ambient temperature sensor is a variable resistor type sensor. It is mounted in the lower radiator grille opening, below the bumper and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor - Description > Page 647 Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the Totally Integrated Power Module (TIPM). Based upon the resistance in the sensor, the instrument cluster or Cab Compartment Node (CCN) display senses a specific voltage on the Controller Area Network (CAN) data bus circuit, which corresponds to a specific temperature. The compass/temperature display unit then displays the proper ambient temperature. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Page 648 Outside Temperature Display Sensor: Testing and Inspection AMBIENT TEMPERATURE SENSOR The thermometer function is supported by the ambient temperature sensor, the Totally Integrated Power Module (TIPM), the Controller Area Network (CAN) data bus circuit, and the instrument cluster or Cab Compartment Node (CCN) compass/temperature display unit. NOTE: The system displays the last known temperature when starting the vehicle and may take some time/mileage to update to an accurate current reading, up to 5 minutes at a maintained speed above 40 mph (64.3 kph). Customers with very short commutes may not get an updated reading before the vehicle is turned off, or if the ignition does not remain in the OFF position for more than 255 minutes (4hrs. 15min.). This strategy was intended to eliminate wildly fluctuating readings and may cause some customer confusion leading to unnecessary diagnostics/parts replacements. If the display shows " _ _ _ ", there is an OPEN or SHORT CIRCUIT that must be repaired. The ambient temperature sensor can be diagnosed using the following Sensor Test. SENSOR TESTING 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. 2. Disconnect the ambient temperature sensor wire harness connector. 3. Measure the resistance of the ambient temperature sensor. At room temperature (approx. 20° C (68°F)), the sensor resistance should be between 9-11 Kilo Ohms (9000-11000 ohms). The sensor resistance should read between these two values. If OK, refer to the appropriate diagnostic information to continue diagnosis of the Totally Integrated Power Module (TIPM), the Controller Area Network (CAN) data bus circuit, and the instrument cluster or CCN. If not OK, replace the inoperative ambient temperature sensor. The most reliable, efficient and accurate means to diagnose the ambient temperature circuit requires the use of a scan tool and the proper diagnostic procedure information. Refer to wiring for the appropriate information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor - Removal Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a suitable tool, release the push pin type retainer that secures the ambient temperature sensor to the lower left side of the front bumper. 3. Disconnect the wire harness connector (1) from the ambient temperature sensor (2). 4. Remove the ambient temperature sensor from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor - Removal > Page 651 Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor Installation INSTALLATION 1. Connect the wire harness connector (1) to the ambient temperature sensor (2). 2. Position the ambient temperature sensor in the vehicle. 3. Install the push pin type retainer that secures the ambient temperature sensor to the lower left side of the front bumper. 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 655 Parking Brake Warning Switch: Diagrams Connector - (INSTRUMENT PANEL) 1 WAY SWITCH-PARKING BRAKE - (INSTRUMENT PANEL) 1 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Backup Lamp Switch: Diagrams Connector (GAS 5 SPD MTX) - (BODY) 2 WAY SWITCH-BACKUP LAMP (GAS 5 SPD MTX) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Backup Lamp Switch - Removal Backup Lamp Switch: Service and Repair Backup Lamp Switch - Removal REMOVAL 1. Lift vehicle on hoist. 2. From bottom side of vehicle, disconnect back-up lamp switch connector (2). 3. Unscrew switch (2) from transaxle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Backup Lamp Switch - Removal > Page 662 Backup Lamp Switch: Service and Repair Backup Lamp Switch - Installation INSTALLATION 1. Install back-up lamp switch (2). Teflon tape or equivalent must be used on switch threads. Tighten switch to 24 Nm (18 ft. lbs.). CAUTION: Do not overtighten switch. 2. Connect back-up lamp switch connector (2). 3. Lower vehicle. 4. Verify back-up lamp operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 666 Brake Light Switch: Diagrams Connector - (BODY) 6 WAY SWITCH-STOP LAMP - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description Brake Light Switch: Description and Operation Stop Lamp Switch - Description DESCRIPTION The stop lamp switch (2) is located under the instrument panel at the brake pedal arm. This switch contains three internal switches controlling various functions of the vehicle, one of them controls operation of the vehicle's brake lamps. Other functions of the internal switches include speed control deactivation and brake sense for the ABS and the brake transmission shift interlock. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description > Page 669 Brake Light Switch: Description and Operation Stop Lamp Switch - Operation OPERATION The stop lamp switch has three internal switches used for various functions. Among these are: - Brake lamp actuation - Speed control deactivation, and - Brake sense for ABS and brake transmission shift interlock When the brake pedal is in the released position, the plunger on the outside of the stop lamp switch is pushed inward by the brake pedal. In this position, the electrical contacts for one internal switch are open while the electrical contacts for other two internal switches are closed. When the brake pedal is pressed, the plunger on the outside of the stop lamp switch extends outward. This action closes the electrical contacts for the one internal switch and opens the contacts for the remaining two switches within the stop lamp switch. The internal switch which closes when the brake pedal is pressed completes the circuit to the brake lamps at the rear of the vehicle, thus allowing illumination of the brake lamps and the center-high-mounted stop lamp (CHMSL). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 670 Brake Light Switch: Testing and Inspection STOP LAMP SWITCH NOTE: Before proceeding with this diagnostic test, verify the adjustment of the stop lamp switch to rule out misadjustment. See: Adjustments If the electrical circuit has been tested and the stop lamp switch is suspected of being faulty, it can be tested using the following method. 1. Remove the switch from the vehicle. See: Service and Repair/Stop Lamp Switch - Removal 2. With the switch in the released position (plunger extended), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as indicated in the figure. 3. Gently push the plunger on the stop lamp switch in until it stops. 4. With the switch in the depressed position (plunger pushed in), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as indicated in the figure. If you do not achieve the results as indicated in both figures, the switch is faulty and must be replaced. 5. Install the switch in the vehicle. See: Service and Repair/Stop Lamp Switch - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 671 Brake Light Switch: Adjustments ADJUSTMENT 1. Depress and hold the brake pedal. 2. Remove the stop switch from its bracket. To do so, rotate the stop lamp switch in a counterclockwise direction approximately 30 degrees from its proper mounting position. Pull the switch rearward and remove it from it's mounting bracket. 3. Hold the stop lamp switch firmly in one hand. Using your other hand, pull outward on the plunger of the switch until it has ratcheted out to its fully extended position. 4. Mount the stop lamp switch into the bracket as follows: Depress the brake pedal as far down as possible. Install the switch in its bracket by aligning the index key on switch with the notch in the square mounting hole of the mounting bracket. Once the switch is fully seated, rotate the switch clockwise approximately 30 degrees to lock the switch into the bracket. CAUTION: Do not use excessive force when pulling back on the brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. 5. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. 6. Check for proper operation of the brake lamps and speed control. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal Brake Light Switch: Service and Repair Stop Lamp Switch - Removal REMOVAL 1. Depress and hold the brake pedal. 2. Remove the stop lamp switch (2) from it's bracket on the brake pedal assembly (6). To do so, rotate the stop lamp switch in a counterclockwise direction approximately 30 degrees from its proper mounting position. Pull the switch rearward and remove it from its mounting bracket. 3. Disconnect the wiring harness connector (1) from the switch. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal > Page 674 Brake Light Switch: Service and Repair Stop Lamp Switch - Installation INSTALLATION NOTE: Prior to installing the stop lamp switch into its bracket, the plunger must be moved to its fully extended position using the procedure described in 1. 1. Hold the stop lamp switch firmly in one hand. Using your other hand, pull outward on the plunger of the switch until it has ratcheted out to its fully extended position. 2. Connect the wiring harness connector (1) to the stop lamp switch (2). 3. Mount the stop lamp switch into the bracket on the brake pedal assembly (6) as follows: Depress the brake pedal as far down as possible. Install the switch in its bracket by aligning the index key on switch with the notch in the square mounting hole of the mounting bracket. Once the switch is fully seated, rotate the switch clockwise approximately 30 degrees to lock the switch into the bracket. CAUTION: Do not use excessive force when pulling back on the brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. 4. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. 5. Check for proper operation of the brake lamps and speed control. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Combination Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing and controls are attached to the Steering Column Control Module (SCCM) (1) by one retaining screw. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single integral interface connector connects the left multi-function switch directly to the SCCM (1). The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. - Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door, the rear flip-up glass, or the liftgate are opened. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 679 - Interior Lamps On - The left multi-function switch control ring provides detent switching to simultaneously illuminate all interior courtesy lamps. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. - Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is damaged or inoperative, the entire switch unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 680 Combination Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch then sends electronic switch status messages over the Local Interconnect Network (LIN) to the Cab Compartment Node (CCN) and then the CCN sends messages over the Controller Area Network (CAN) data bus to the Totally Integrated Power Module (TIPM) other electronic modules in the vehicle. For lighting and wiper function it sends the messages over the LIN bus to the CCN and the CCN puts them out on the CAN bus to the other modules. The left switch has the microprocessor for all communication to the TIPM. The SCCM is composed of a clockspring and left lighting switch and a right wiper switch. The TIPM, controls the lighting and wiper functions. The left multi-function switch can be diagnosed using LIN based diagnostic tools and methods. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp On position is also selected, and will automatically move the control knob to the front fog lamps Off position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp beams are selected when the left multi-function switch control stalk is pushed forward. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Each time the control stalk is actuated in this manner, the headlamp beams are toggled from the current selection to the opposite selection. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled rearward to a momentary position just short of the beam selection detent position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the previously selected beams will be restored when the control stalk is released. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps On position is also selected, and will automatically move the control knob to the rear fog lamp Off position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary "lane change" position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring, rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps defeat detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 681 CAN data bus to the other electronic modules in the vehicle. - Interior Lamps On - The interior lamps on feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps On detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Parade Mode - The parade or funeral mode is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the parade mode is requested when the left multi-function switch control sleeve is rotated to the parade mode detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Combination Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL NOTE: It is not necessary to remove the Steering Column Control Module (SCCM) from the steering column to replace the left multi-function switch (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag or steering column components. 2. Remove both the upper and lower shrouds from the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the one screw (2) that secures the left multi-function switch (3) on the right side of the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 684 4. Pull the switch (2) straight away from the clockspring (1) far enough to access the electrical connector (3) to disconnect it. 5. Disconnect the instrument panel wiring harness from the back of the left multi-function switch. 6. Remove the switch (2) from the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 685 Combination Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION 1. Position the left multi-function switch in the slot in the back of the clockspring (1) and connect the switch connector (3). 2. Connect the instrument panel wiring harness connector to the back of the left multi-function switch. 3. Align switch (3) with the clockspring (1) and slide toward steering column. 4. Install the screw (2) that secures the switch (3) to the clockspring (1). 5. Install the upper and lower shrouds onto the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Fog/Driving Lamp Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing and controls are attached to the Steering Column Control Module (SCCM) (1) by one retaining screw. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single integral interface connector connects the left multi-function switch directly to the SCCM (1). The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. - Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door, the rear flip-up glass, or the liftgate are opened. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 690 - Interior Lamps On - The left multi-function switch control ring provides detent switching to simultaneously illuminate all interior courtesy lamps. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. - Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is damaged or inoperative, the entire switch unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 691 Fog/Driving Lamp Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch then sends electronic switch status messages over the Local Interconnect Network (LIN) to the Cab Compartment Node (CCN) and then the CCN sends messages over the Controller Area Network (CAN) data bus to the Totally Integrated Power Module (TIPM) other electronic modules in the vehicle. For lighting and wiper function it sends the messages over the LIN bus to the CCN and the CCN puts them out on the CAN bus to the other modules. The left switch has the microprocessor for all communication to the TIPM. The SCCM is composed of a clockspring and left lighting switch and a right wiper switch. The TIPM, controls the lighting and wiper functions. The left multi-function switch can be diagnosed using LIN based diagnostic tools and methods. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp On position is also selected, and will automatically move the control knob to the front fog lamps Off position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp beams are selected when the left multi-function switch control stalk is pushed forward. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Each time the control stalk is actuated in this manner, the headlamp beams are toggled from the current selection to the opposite selection. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled rearward to a momentary position just short of the beam selection detent position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the previously selected beams will be restored when the control stalk is released. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps On position is also selected, and will automatically move the control knob to the rear fog lamp Off position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary "lane change" position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring, rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps defeat detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 692 CAN data bus to the other electronic modules in the vehicle. - Interior Lamps On - The interior lamps on feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps On detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Parade Mode - The parade or funeral mode is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the parade mode is requested when the left multi-function switch control sleeve is rotated to the parade mode detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Fog/Driving Lamp Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL NOTE: It is not necessary to remove the Steering Column Control Module (SCCM) from the steering column to replace the left multi-function switch (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag or steering column components. 2. Remove both the upper and lower shrouds from the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the one screw (2) that secures the left multi-function switch (3) on the right side of the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 695 4. Pull the switch (2) straight away from the clockspring (1) far enough to access the electrical connector (3) to disconnect it. 5. Disconnect the instrument panel wiring harness from the back of the left multi-function switch. 6. Remove the switch (2) from the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 696 Fog/Driving Lamp Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION 1. Position the left multi-function switch in the slot in the back of the clockspring (1) and connect the switch connector (3). 2. Connect the instrument panel wiring harness connector to the back of the left multi-function switch. 3. Align switch (3) with the clockspring (1) and slide toward steering column. 4. Install the screw (2) that secures the switch (3) to the clockspring (1). 5. Install the upper and lower shrouds onto the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Hazard Warning Switch - Description Hazard Warning Switch: Description and Operation Hazard Warning Switch - Description DESCRIPTION The hazard switch is located in the Accessory Switch Bank Module (ASBM) just below the heater a/c controls, in the instrument panel center stack. This switch is the control for the hazard warning lighting. The only visible component of the switch is the control push button that is located just to the left of the Passenger Airbag Disabled Light (PADL) indicator. On BUX models, the hazard switch is located to the left of the Headlamp Leveling Switch, in the ASBM. The hazard switch cannot be adjusted or repaired. If the switch is ineffective or damaged, the entire ASBM must be replaced See: Sensors and Switches - Accessories and Optional Equipment/Integrated Accessory Switch Assembly/Service and Repair/Instrument Cluster Switch Pod - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Hazard Warning Switch - Description > Page 701 Hazard Warning Switch: Description and Operation Hazard Warning Switch - Operation OPERATION The hazard switch features a push-push type latching push button. When the push button is in its latched (lowered) position the switch contacts are open, and when the push button is in its unlatched (raised) position the switch contacts are closed. The hazard switch receives a ground on one terminal and provides a ground signal output to the Totally Integrated Power Module (TIPM) ) whenever the switch contacts are closed. The TIPM responds to this input by controlling a battery voltage output and the flash rate for each of the right and left turn signal lamps, then sends an electronic hazard switch status message over the Controller Area Network (CAN) data bus to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) to control the illumination and flash rate of the right and left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. The hazard switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Headlamp Dimmer Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing and controls are attached to the Steering Column Control Module (SCCM) (1) by one retaining screw. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single integral interface connector connects the left multi-function switch directly to the SCCM (1). The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. - Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door, the rear flip-up glass, or the liftgate are opened. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 706 - Interior Lamps On - The left multi-function switch control ring provides detent switching to simultaneously illuminate all interior courtesy lamps. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. - Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is damaged or inoperative, the entire switch unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 707 Headlamp Dimmer Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch then sends electronic switch status messages over the Local Interconnect Network (LIN) to the Cab Compartment Node (CCN) and then the CCN sends messages over the Controller Area Network (CAN) data bus to the Totally Integrated Power Module (TIPM) other electronic modules in the vehicle. For lighting and wiper function it sends the messages over the LIN bus to the CCN and the CCN puts them out on the CAN bus to the other modules. The left switch has the microprocessor for all communication to the TIPM. The SCCM is composed of a clockspring and left lighting switch and a right wiper switch. The TIPM, controls the lighting and wiper functions. The left multi-function switch can be diagnosed using LIN based diagnostic tools and methods. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp On position is also selected, and will automatically move the control knob to the front fog lamps Off position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp beams are selected when the left multi-function switch control stalk is pushed forward. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Each time the control stalk is actuated in this manner, the headlamp beams are toggled from the current selection to the opposite selection. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled rearward to a momentary position just short of the beam selection detent position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the previously selected beams will be restored when the control stalk is released. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps On position is also selected, and will automatically move the control knob to the rear fog lamp Off position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary "lane change" position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring, rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps defeat detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 708 CAN data bus to the other electronic modules in the vehicle. - Interior Lamps On - The interior lamps on feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps On detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Parade Mode - The parade or funeral mode is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the parade mode is requested when the left multi-function switch control sleeve is rotated to the parade mode detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Headlamp Dimmer Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL NOTE: It is not necessary to remove the Steering Column Control Module (SCCM) from the steering column to replace the left multi-function switch (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag or steering column components. 2. Remove both the upper and lower shrouds from the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the one screw (2) that secures the left multi-function switch (3) on the right side of the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 711 4. Pull the switch (2) straight away from the clockspring (1) far enough to access the electrical connector (3) to disconnect it. 5. Disconnect the instrument panel wiring harness from the back of the left multi-function switch. 6. Remove the switch (2) from the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 712 Headlamp Dimmer Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION 1. Position the left multi-function switch in the slot in the back of the clockspring (1) and connect the switch connector (3). 2. Connect the instrument panel wiring harness connector to the back of the left multi-function switch. 3. Align switch (3) with the clockspring (1) and slide toward steering column. 4. Install the screw (2) that secures the switch (3) to the clockspring (1). 5. Install the upper and lower shrouds onto the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Headlamp Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing and controls are attached to the Steering Column Control Module (SCCM) (1) by one retaining screw. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single integral interface connector connects the left multi-function switch directly to the SCCM (1). The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. - Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door, the rear flip-up glass, or the liftgate are opened. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 717 - Interior Lamps On - The left multi-function switch control ring provides detent switching to simultaneously illuminate all interior courtesy lamps. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. - Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is damaged or inoperative, the entire switch unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 718 Headlamp Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch then sends electronic switch status messages over the Local Interconnect Network (LIN) to the Cab Compartment Node (CCN) and then the CCN sends messages over the Controller Area Network (CAN) data bus to the Totally Integrated Power Module (TIPM) other electronic modules in the vehicle. For lighting and wiper function it sends the messages over the LIN bus to the CCN and the CCN puts them out on the CAN bus to the other modules. The left switch has the microprocessor for all communication to the TIPM. The SCCM is composed of a clockspring and left lighting switch and a right wiper switch. The TIPM, controls the lighting and wiper functions. The left multi-function switch can be diagnosed using LIN based diagnostic tools and methods. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp On position is also selected, and will automatically move the control knob to the front fog lamps Off position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp beams are selected when the left multi-function switch control stalk is pushed forward. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Each time the control stalk is actuated in this manner, the headlamp beams are toggled from the current selection to the opposite selection. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled rearward to a momentary position just short of the beam selection detent position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the previously selected beams will be restored when the control stalk is released. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps On position is also selected, and will automatically move the control knob to the rear fog lamp Off position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary "lane change" position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring, rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps defeat detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 719 CAN data bus to the other electronic modules in the vehicle. - Interior Lamps On - The interior lamps on feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps On detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Parade Mode - The parade or funeral mode is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the parade mode is requested when the left multi-function switch control sleeve is rotated to the parade mode detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Headlamp Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL NOTE: It is not necessary to remove the Steering Column Control Module (SCCM) from the steering column to replace the left multi-function switch (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag or steering column components. 2. Remove both the upper and lower shrouds from the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the one screw (2) that secures the left multi-function switch (3) on the right side of the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 722 4. Pull the switch (2) straight away from the clockspring (1) far enough to access the electrical connector (3) to disconnect it. 5. Disconnect the instrument panel wiring harness from the back of the left multi-function switch. 6. Remove the switch (2) from the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 723 Headlamp Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION 1. Position the left multi-function switch in the slot in the back of the clockspring (1) and connect the switch connector (3). 2. Connect the instrument panel wiring harness connector to the back of the left multi-function switch. 3. Align switch (3) with the clockspring (1) and slide toward steering column. 4. Install the screw (2) that secures the switch (3) to the clockspring (1). 5. Install the upper and lower shrouds onto the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 727 Horn Switch: Diagrams Connector - (STEERING WHEEL) 2 WAY SWITCH-HORN - (STEERING WHEEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Horn Switch - Description Horn Switch: Description and Operation Horn Switch - Description DESCRIPTION WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and cautions before servicing the horn switch. The horn switch is mounted inside the driver airbag. The horn switch has three contacts that are grounded when the driver airbag is depressed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Horn Switch - Description > Page 730 Horn Switch: Description and Operation Horn Switch - Operation OPERATION When the Driver Airbag Cover is pressed, the horn switch makes contact to ground. The ground signal is carried to the horn relay and the horn sounds. The horn switch grounds to the airbag housing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Horn Switch - Removal Horn Switch: Service and Repair Horn Switch - Removal REMOVAL WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and cautions before servicing the horn switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Removal. 3. Disconnect the connector from the clockspring. 4. Remove the three mounting fasteners. 5. Remove the horn switch. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Horn Switch - Removal > Page 733 Horn Switch: Service and Repair Horn Switch - Installation INSTALLATION 1. Install the horn switch. 2. Install the three mounting fasteners. 3. Connect the electrical connector to the clockspring. 4. Install the driver airbag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Installation 5. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 739 Accelerator Pedal Position Sensor: Diagrams Connector - (BODY) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1/1 (Powertrain) 3 Way Camshaft Position Sensor: Diagrams Camshaft Position Sensor 1/1 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CAMSHAFT 1/1 POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1/1 (Powertrain) 3 Way > Page 745 Camshaft Position Sensor: Diagrams Camshaft Position Sensor 1/2 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CAMSHAFT 1/2 POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Description DESCRIPTION The camshaft position sensors are mounted to the front and rear of the cylinder head. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description > Page 748 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Operation OPERATION NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt output reference circuit. A ground for the sensor is provided through the sensor return circuit. The PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the camshaft position sensor. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal Front FRONT 1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor electrical connector. 2. Disconnect negative battery cable. 3. Disconnect electrical connector from camshaft position sensor. 4. Remove camshaft position sensor mounting screws. 5. Remove sensor. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 751 1. Disconnect negative battery cable. 2. Disconnect electrical connector at sensor. 3. Remove nut retaining heat shield. 4. Pull heat shield out to uncover sensor. 5. Remove mounting bolt. 6. Remove sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 752 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation Front FRONT 1. Lubricate sensor o-ring. 2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9 Nm (79.5 in. lbs.). 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install the negative battery cable. 5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical connector. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 753 1. Lubricate sensor o-ring. 2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. 3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Carefully attach electrical connector to camshaft position sensor. Feel for positive lock (click). Installation at angle may damage the sensor pins. 5. Install heat shield onto mounting stud. 6. Install heat shield retaining nut and tighten. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 > Page 758 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor 2 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 > Page 759 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way > Page 762 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 2 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 2 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 763 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. ENGINE COOLANT TEMPERATURE SENSOR WIRING OR CONNECTORS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 764 NOTE: Diagnose and repair any ECT circuit DTCs before proceeding with this test. NOTE: Allow the engine to cool to ambient temperature before proceeding. 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature sensor(s) and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Turn the ignition on. 5. Monitor the scan tool data relative to the sensor(s) and wiggle test the wiring and connectors. 6. Look for the data to change or for a DTC to set during the wiggle test. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. ENGINE COOLANT LEVEL AND CONDITION WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Check the engine coolant level and the condition of the engine coolant. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. THERMOSTAT WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Using the appropriate service information, determine the proper opening temperature of the thermostat. 2. With the scan tool, read the Engine Coolant Temperature Sensor value for each sensor. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 3. Monitor the sensor values on the scan tool. 4. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: Each thermostat should open at the temperature specified. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 765 Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. ENGINE COOLANT TEMPERATURE SENSOR NOTE: Allow the engine to cool to ambient temperature before proceeding. WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. With the scan tool, read the Engine Coolant Temperature Sensor value for each sensor. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 2. Monitor each sensor value on the scan tool and the actual coolant temperature with a thermometer. 3. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The sensor value transition should be smooth as the engine reaches operating temperature. The thermometer reading and the coolant temperature values on the scan tool should remain relatively close. Were any problems found? Yes - Go to 5. No - Test complete. 5. ECT SIGNAL CIRCUIT HIGH RESISTANCE NOTE: Perform this procedure for the sensor where erratic sensor values were detected in the previous test step. 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the ECT Signal circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 No - Repair the ECT Signal circuit for excessive resistance. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 766 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the Sensor Ground circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. ENGINE COOLANT TEMPERATURE SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Engine Coolant Temperature Sensor. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CRANKSHAFT POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The crankshaft position sensor mounts to the rear of the engine block near the transmission. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 772 Crankshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor (2). The PCM determines which cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth and notches (1), including one long reference tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal REMOVAL The Crankshaft Position Sensor is in the rear of the engine block near the transmission. 1. Remove the engine cover (1). 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner body (1) See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 775 4. Disengage the upstream O2 sensor wire harness retainer (1) and crankshaft position sensor wire harness retainer (2) from the heat shield (3). 5. Remove one nut (1) and two heat shield retaining bolts (2). 6. Remove heat shield (3). 7. Remove the crankshaft position sensor mounting bolt. 8. Remove sensor with the wire harness attached. 9. Unlock and disconnect the electrical connector from the crankshaft position sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 776 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation INSTALLATION 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Using a twisting motion, install the crankshaft position sensor. 3. Install the crankshaft position sensor bolt. Tighten the bolt to 9 Nm (80 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 777 5. Install the heat shield (3) with one nut (1) and two heat shield retaining bolts (2). 6. Install the upstream O2 sensor wire harness retainer (1) and crankshaft position sensor wire harness retainer (2) to the heat shield (3). 7. Install the air cleaner body (1) See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation 8. Connect the negative battery cable. 9. Install the engine cover (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Remove engine cover. 2. Disconnect and isolate negative batter cable. 3. Disconnect upstream DPF temperature sensor electrical connector. 4. Remove upstream DPF temperature sensor. 5. Disconnect downstream DPF temperature sensor electrical connector. 6. Remove downstream DPF temperature sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 782 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Position DPF downstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 2. Connect downstream temperature sensor electrical connector. 3. Position DPF upstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 4. Connect upstream temperature sensor electrical connector. 5. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Sensor: Service and Repair Removal EXHAUST PRESSURE SENSOR 1. Disconnect and isolate negative battery cable. 2. Remove electrical connector at pressure differential sensor (2). 3. Remove upstream exhaust pressure tube (4) from catalytic converter 4. Remove downstream pressure tube (6) from catalytic converter. 5. Remove pressure differential sensor mounting bolt. 6. Remove pressure differential sensor (2) and tubing (7) from vehicle. 7. Remove tubing (7) from pressure differential sensor (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal > Page 787 Exhaust Pressure Sensor: Service and Repair Installation EXHAUST PRESSURE SENSOR 1. Install tubing (7) on pressure differential sensor (2). 2. Position pressure differential sensor (2) and tubing (7). 3. Install pressure differential sensor mounting bolt (3). Tighten to 10 Nm (89 in. lbs.). 4. Install downstream pressure tube (6) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.). 5. Install upstream pressure tube (4) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.) 6. Position electrical connector (1) into bracket. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 791 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way Fuel Level Sensor: Diagrams Fuel Pump Module (FWD) (Body) 4 Way Connector (FWD) - (BODY) 4 WAY MODULE-FUEL PUMP (FWD) - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way > Page 794 Fuel Level Sensor: Diagrams Fuel Pump Module C1 (AWD) (Body) 5 Way Connector C1 (AWD) - (BODY) 5 WAY MODULE-FUEL PUMP (AWD) - (BODY) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way > Page 795 Fuel Level Sensor: Diagrams Fuel Pump Module C2 (AWD) (Body) 2 Way Connector C2 (AWD) - (BODY) 2 WAY MODULE-FUEL PUMP (AWD) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Level Sensor: Description and Operation Fuel Pump Module - Description DESCRIPTION - FUEL PUMP MODULE The fuel pump module is located on the top left side of the fuel tank. The fuel pump module contains the following components: - Mounting flange - Electric fuel pump - Fuel pump reservoir - Inlet strainer - Fuel pressure regulator - Fuel level sending unit - Fuel filter The fuel level sending unit (3) is the only serviceable component of the fuel pump module. If the electric fuel pump, fuel pressure regulator or fuel filter requires service, the fuel pump module must be replaced as an assembly. DESCRIPTION The fuel pump module is installed in the top of the fuel tank. The fuel pump module contains the following: - Electric fuel pump - Fuel pump reservoir Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 798 - Inlet strainer - Fuel pressure regulator - Fuel gauge sending unit - Fuel supply line connection - Fuel Filter NOTE: The fuel level sending unit is the only serviceable item. If the fuel pump, fuel pressure regulator or fuel filters need service, replace the fuel pump module as an assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 799 Fuel Level Sensor: Description and Operation Fuel Pump Module - Operation OPERATION - FUEL PUMP MODULE An electric fuel pump is located within the fuel pump module. The electric fuel pump is a positive displacement, immersible pump with a permanent magnet electric motor capable of creating 860 kPa (125 psi) of operating pressure. The fuel pressure regulator limits fuel pressure to 400 kPa (58 psi). The fuel gauge is controlled by the instrument cluster circuit board based upon cluster programming and a hard wired input received by the cluster from the fuel level sending unit on the module in the fuel tank. The instrument cluster continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. This information is available to other vehicle control modules via the Controller Area Network (CAN) data bus. Fuel gauge diagnosis is conducted as part ofthe instrument cluster circuitry. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Level Sensor: Service and Repair Fuel Pump Module - Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. 1. Perform Fuel System Pressure Release procedure. See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose. 3. Remove the negative battery cable. 4. Remove the rear seat cushion. 5. Rear seat cushion loose. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 802 6. Remove plastic cover. 7. Clean top of tank to remove loose dirt and debris. 8. Use special tool #9340 to remove left side module lock ring. 9. Note the fuel pump location on the top of the fuel tank. NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 803 10. Pull module up out of fuel tank, make sure that you do not spill fuel inside of vehicle. 11. Drain fuel from fuel pump module. Do not spill fuel in interior of vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 804 Fuel Level Sensor: Service and Repair Fuel Pump Module - Installation INSTALLATION NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. 1. Wipe seal area of tank clean. Place a new seal between the tank threads and the pump module opening. 2. Install module. 3. Position fuel pump module in tank. Make sure the alignment tab lines up on the fuel tank and pump module for Gas or Diesel fuel tanks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 805 4. While holding the pump module in position, install lock ring and use special tool Spanner Wrench #9340 to tighten lock ring. 5. Install plastic cover. 6. Install rear cushion. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 806 7. Install the negative battery cable. 8. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. 9. Fill fuel tank with clean fuel. Use the Scan Tool to pressurize the system and check for leaks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 810 Intake Air Temperature Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-INTAKE AIR TEMPERATURE (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect electrical connector from sensor. 3. Remove the sensor clean air duct. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 813 Intake Air Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install inlet air temperature sensor into the clean air duct. 2. Connect electrical connector to sensor. 3. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 817 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 818 Knock Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-KNOCK (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal REMOVAL The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Disconnect the negative battery cable. 2. Remove the bolt holding the knock sensor. 3. Remove sensor with electrical connector attached. 4. Disconnect electrical connector from knock sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 821 5. Remove the knock sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 822 Knock Sensor: Service and Repair Knock Sensor - Installation INSTALLATION The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Attach electrical connector to knock sensor. 2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening effects knock sensor performance, possibly causing improper spark control. 3. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 826 Manifold Pressure/Vacuum Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-MAP (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Operation Manifold Pressure/Vacuum Sensor: Description and Operation Operation OPERATION The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 volt and full scale is 4.5 volt. For a pressure swing of 0 - 15 psi the voltage changes 4.0 volt. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key on. The difference between current and what it was at key on is manifold vacuum. During key On (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in your work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC1 transmissions only, via the PCI bus) - Idle speed - Decel fuel shutoff The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 88 kPa (26 in. Hg). Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 101 kPa (29.92 in. Hg). For every 30.5 meters (100 feet) of altitude barometric pressure drops.33 kPa (0.10 in. Hg). If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Operation > Page 829 Manifold Pressure/Vacuum Sensor: Description and Operation Description DESCRIPTION The MAP sensor mounts to the intake manifold. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Page 830 Manifold Pressure/Vacuum Sensor: Testing and Inspection CHECKING THE MAP SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. MAP SENSOR WIRING OR CONNECTORS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Page 831 NOTE: Diagnose and repair any MAP Sensor circuit DTCs before proceeding with this test. NOTE: Diagnose and repair any sensor supply or system voltage DTCs before proceeding with this test. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. MAP VACUUM/BAROMETRIC PRESSURE 1. With a scan tool, read the Barometric Pressure. NOTE: The Barometric Pressure should be approximately equal to the actual barometric pressure. If necessary, compare the Barometric Pressure value of the tested vehicle to the value of a known good vehicle of a similar make and model. 2. Connect a vacuum gauge to a manifold vacuum source. 3. Start the engine. NOTE: If engine will not idle, maintain a constant RPM above idle. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 4. With the scan tool, read the MAP Sensor vacuum. NOTE: The scan tool reading for MAP vacuum should be within 1" of the vacuum gauge reading. Were any problems found? Yes - Go to 4 No - Go to 3 3. MAP SENSOR VOLTAGE 1. With the scan tool, monitor the MAP Sensor signal voltage. 2. With the engine idling in neutral or park, snap the throttle. NOTE: The MAP Sensor signal voltage should change from below 2.0 volts at idle to above 3.5 volts at wide open throttle. Were any problems found? Yes - Go to 4 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Page 832 No - Test complete. 4. (F856) 5 VOLT SUPPLY CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (F856) 5 Volt Supply circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 5 No - Repair the (F856) 5 Volt Supply circuit for excessive resistance. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 5. (K1) MAP SIGNAL CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K1) MAP Signal circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 No - Repair the (K1) MAP Signal circuit for excessive resistance. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the MAP Sensor harness connector and by Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Page 833 probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the (K900) Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. MAP SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the MAP Sensor. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect electrical connector from manifold absolute pressure (MAP) sensor. 3. Remove screw from MAP sensor. 4. Remove MAP sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 836 Manifold Pressure/Vacuum Sensor: Service and Repair Installation INSTALLATION 1. Install manifold absolute pressure (MAP) sensor to intake manifold. 2. Tighten screw to 4.5 Nm (40 in. lbs.). 3. Connect electrical connector to sensor. 4. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 841 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Powertrain) 4 Way Oxygen Sensor: Diagrams Oxygen Sensor 1/1 (Powertrain) 4 Way Connector (GAS) - (POWERTRAIN) 4 WAY SENSOR-OXYGEN 1/1 (GAS) - (POWERTRAIN) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Powertrain) 4 Way > Page 844 Oxygen Sensor: Diagrams Oxygen Sensor 1/2 (Engine Compartment) 4 Way Connector (GAS) - (ENGINE COMPARTMENT) 4 WAY SENSOR-OXYGEN 1/2 (GAS) - (ENGINE COMPARTMENT) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 845 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Oxygen Sensor: Description and Operation Description DESCRIPTION The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. The downstream heated oxygen sensor threads into the system depending on emission package. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description > Page 848 Oxygen Sensor: Description and Operation Operation OPERATION Separate upstream and downstream grounds are used on the NGC vehicles (4 Cyl.). As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The O2 sensors produce a constant 2.5 volts on NGC vehicles, depending upon the oxygen content of the exhaust gas. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produce a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, which can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2 sensor's input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The NGC Controller has a common ground for the heater in the O2S. 12 volts is supplied to the heater in the O2S by the NGC controller. Both the upstream and downstream O2 sensors for NGC are pulse width modulation (PWM). NOTE: When replacing an O2 Sensor, the PCM RAM memory must be cleared, either by disconnecting the PCM C-1 connector or momentarily disconnecting the Battery negative terminal. The NGC learns the characteristics of each O2 heater element and these old values should be cleared when installing a new O2 sensor. The customer may experience driveability issues if this is not performed. UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 2.5 to 3.5 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 2.5 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 3.5 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. This is also used to establish the upstream O2 goal voltage (switching point). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 849 Oxygen Sensor: Testing and Inspection CHECKING THE OXYGEN SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. OXYGEN SENSOR, WIRING OR CONNECTORS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 850 NOTE: Diagnose and repair any O2 sensor or rationality DTCs before proceeding with this test. NOTE: When performing this procedure as part of another diagnostic process, it may be necessary to repeat this test for all of the oxygen sensors on the vehicle. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen sensor and the Powertrain Control Module (PCM). 3. Look for any chafed, pierced, pinched or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. OXYGEN SENSOR VOLTAGE 1. Start the engine and allow it to reach normal operating temperature. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 2. With a scan tool, monitor all O2 Sensor voltage readings. Is the voltage switching between 2.5 and 3.4 volts for all O2 sensors? Yes - Go To 3 No - Go To 4 3. O2 SENSOR HEATER OPERATION 1. Turn the ignition off. NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0 volts. 2. Turn the ignition on. 3. With a scan tool, actuate the O2 Sensor heater. 4. With the scan tool, monitor O2 Sensor voltage for at least two minutes. Does the voltage stay above 4.5 volts? Yes - Go To 4 No - Test complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 851 4. O2 SENSOR 1. Turn the ignition off. NOTE: Check for contaminants that may cause improper O2 Sensor operation, such as contaminated fuel, unapproved silicone, or evidence of oil or coolant. 2. Disconnect the O2 Sensor harness connector. 3. Turn the ignition on. 4. With a scan tool, monitor the O2 Sensor voltage. NOTE: The voltage should be approximately 5.0 volts with the connector disconnected. 5. Connect a jumper wire between the signal circuit and the return circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from 5.0 volts to 2.5 volts with the jumper wire in place. Is the O2 Sensor voltage displayed on the scan tool as described? Yes - Replace the O2 Sensor. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 5 5. O2 SENSOR SIGNAL CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Signal circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor signal circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 6 6. O2 SENSOR RETURN CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Return circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor return circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 7 7. POWERTRAIN CONTROL MODULE (PCM) 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the O2 sensor and the PCM. 2. Look for any chafed, pierced, pinched or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Monitor the scan tool data relative to the components tested in this procedure and wiggle test the wiring and connectors. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 852 5. Look for the data to change or for a DTC to set during the wiggle test. 6. Search for any Technical Service Bulletins (TSBs) that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Replace and program the Powertrain Control Module (PCM). - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal Oxygen Sensor: Service and Repair Removal 2.4L DOWNSTREAM OXYGEN SENSOR (1/2) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wires going into oxygen sensor. Damage to the oxygen sensor may occur. NOTE: Use an oxygen sensor (O2S) removal tool for this procedure. 1. Raise and support vehicle. 2. Disconnect O2S wire harness mounting clips from engine or body, if equipped. 3. Disconnect O2S pigtail harness connector (1) from engine wiring harness. 4. Remove O2S (3) from exhaust pipe (2). UPSTREAM OXYGEN SENSOR (1/1) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wires going into oxygen sensor. Damage to the oxygen Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 855 sensor may occur. NOTE: Use an oxygen sensor (O2S) removal tool for this procedure. 1. Raise and support vehicle. 2. Disconnect O2S wire harness mounting clips from engine or body, if equipped. 3. Disconnect O2S pigtail harness connector (1) from engine wiring harness. 4. Remove O2S (3) from maniverter (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 856 Oxygen Sensor: Service and Repair Installation 2.4L DOWNSTREAM OXYGEN SENSOR (1/2) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted back to their original positions on engine or body to prevent mechanical damage to wiring. NOTE: Use an O2S removal tool for this procedure. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new O2S. 1. Install O2 sensor (3) to exhaust pipe (2). Tighten to 41 Nm (30 ft. lbs.). 2. Connect O2 sensor pigtail harness connector (1) to engine wiring harness. 3. Connect O2S wire harness mounting clips to engine or body, if equipped. UPSTREAM OXYGEN SENSOR (1/1) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 857 CAUTION: When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted back to their original positions on engine or body to prevent mechanical damage to wiring. NOTE: Use an O2S removal tool for this procedure. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new O2S. 1. Install O2 sensor (3) to maniverter (2). Tighten to 41 Nm (30 ft. lbs.). 2. Connect O2 sensor pigtail harness connector (1) to engine wiring harness. 3. Connect O2S wire harness mounting clips to engine or body, if equipped. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams Vehicle Speed Sensor: Diagrams Connector (GAS MTX) - (POWERTRAIN) 3 WAY SENSOR-VEHICLE SPEED (GAS MTX) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Remove engine cover. 2. Disconnect and isolate negative batter cable. 3. Disconnect upstream DPF temperature sensor electrical connector. 4. Remove upstream DPF temperature sensor. 5. Disconnect downstream DPF temperature sensor electrical connector. 6. Remove downstream DPF temperature sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 866 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Position DPF downstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 2. Connect downstream temperature sensor electrical connector. 3. Position DPF upstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 4. Connect upstream temperature sensor electrical connector. 5. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 871 Accelerator Pedal Position Sensor: Diagrams Connector - (BODY) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Description and Operation > Oil Pressure Switch - Description Oil Pressure Switch (For Fuel Pump): Description and Operation Oil Pressure Switch - Description DESCRIPTION The oil pressure switch is located on the left front side of the engine block. The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Description and Operation > Oil Pressure Switch - Description > Page 876 Oil Pressure Switch (For Fuel Pump): Description and Operation Oil Pressure Switch - Operation OPERATION The oil pressure switch is normally "Closed." The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig. The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Raise and support the vehicle See: Maintenance/Vehicle Lifting/Service and Repair 3. Remove the splash shield from the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 4. Remove the accessory drive belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal 5. Remove the three bolts (2) and reposition the A/C compressor (1). 6. Disconnect the oil pressure switch electrical connector. 7. Remove the oil pressure switch using oil pressure socket C-4597 (1) or equivalent. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal > Page 879 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Installation INSTALLATION NOTE: If the oil pressure switch is removed, it must be replaced with a new switch. CAUTION: The oil pressure switch has tapered threads, over tightening could crack the engine block. 1. Install the oil pressure switch using oil pressure socket C-4597 (1) or equivalent. Tighten switch to 8 Nm (71 in. lbs.). 2. Connect the oil pressure switch electrical connector. 3. Position the A/C compressor (1) and install three mounting bolts (2). Tighten bolts to 25 Nm (18 ft. lbs.). 4. Install the accessory drive belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation 5. Install the splash shield to the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 6. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1/1 (Powertrain) 3 Way Camshaft Position Sensor: Diagrams Camshaft Position Sensor 1/1 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CAMSHAFT 1/1 POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1/1 (Powertrain) 3 Way > Page 886 Camshaft Position Sensor: Diagrams Camshaft Position Sensor 1/2 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CAMSHAFT 1/2 POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Description DESCRIPTION The camshaft position sensors are mounted to the front and rear of the cylinder head. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description > Page 889 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Operation OPERATION NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt output reference circuit. A ground for the sensor is provided through the sensor return circuit. The PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the camshaft position sensor. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal Front FRONT 1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor electrical connector. 2. Disconnect negative battery cable. 3. Disconnect electrical connector from camshaft position sensor. 4. Remove camshaft position sensor mounting screws. 5. Remove sensor. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 892 1. Disconnect negative battery cable. 2. Disconnect electrical connector at sensor. 3. Remove nut retaining heat shield. 4. Pull heat shield out to uncover sensor. 5. Remove mounting bolt. 6. Remove sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 893 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation Front FRONT 1. Lubricate sensor o-ring. 2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9 Nm (79.5 in. lbs.). 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install the negative battery cable. 5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical connector. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 894 1. Lubricate sensor o-ring. 2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. 3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Carefully attach electrical connector to camshaft position sensor. Feel for positive lock (click). Installation at angle may damage the sensor pins. 5. Install heat shield onto mounting stud. 6. Install heat shield retaining nut and tighten. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CRANKSHAFT POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The crankshaft position sensor mounts to the rear of the engine block near the transmission. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 900 Crankshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor (2). The PCM determines which cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth and notches (1), including one long reference tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal REMOVAL The Crankshaft Position Sensor is in the rear of the engine block near the transmission. 1. Remove the engine cover (1). 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner body (1) See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 903 4. Disengage the upstream O2 sensor wire harness retainer (1) and crankshaft position sensor wire harness retainer (2) from the heat shield (3). 5. Remove one nut (1) and two heat shield retaining bolts (2). 6. Remove heat shield (3). 7. Remove the crankshaft position sensor mounting bolt. 8. Remove sensor with the wire harness attached. 9. Unlock and disconnect the electrical connector from the crankshaft position sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 904 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation INSTALLATION 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Using a twisting motion, install the crankshaft position sensor. 3. Install the crankshaft position sensor bolt. Tighten the bolt to 9 Nm (80 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 905 5. Install the heat shield (3) with one nut (1) and two heat shield retaining bolts (2). 6. Install the upstream O2 sensor wire harness retainer (1) and crankshaft position sensor wire harness retainer (2) to the heat shield (3). 7. Install the air cleaner body (1) See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation 8. Connect the negative battery cable. 9. Install the engine cover (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Removal REMOVAL WARNING: Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. This will disable the front airbag system. Failure to disconnect the battery could result in accidental front airbag module deployment and possible personal injury.Do not place a non-deployed airbag face down on a hard surface as the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. 1. Remove air cleaner fresh air duct (2) and disconnect and isolate negative battery cable at battery, See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal. 2. Remove upper (1) and lower (2) steering column shrouds,See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 911 3. Remove steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 4. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket integral to the right side of the clockspring (3) on the steering column. 5. Slide the switch away from the clockspring far enough to disengage the slide tab on the bottom of the switch housing from the channel formation in the mounting bracket. Position the multi-function switch (1) aside. 6. Position steering column to the full down position. 7. Position ignition key to the RUN position. 8. Remove screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 9. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and position the SKREEM/WCM (2) back on the lock cylinder housing (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 912 10. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing. Depress the key cylinder retaining tab. 11. Pull key cylinder (3) and key (2) straight out of the lock cylinder housing as one unit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 913 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Installation INSTALLATION 1. Place actuator in the lock cylinder housing to the RUN position (if not already there). 2. Insert key into key cylinder and turn key cylinder to the RUN position. 3. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 4. Slide key cylinder into the lock cylinder housing until key cylinder retaining tab locks the cylinder into place. 5. Rotate key back and forth (OFF to START), then remove and reinstall it, making sure key cylinder and lock cylinder housing operate properly. 6. Slide the ring of SKREEM/WCM (2) over lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 7. Install screw (1) fastening the SKREEM/WCM (2) to lock cylinder housing (3). Tighten screw to 2.5 Nm (22 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 914 8. Install and tighten the screw (2) that secures the mounting tab on the back of the right multi-function switch (1) to the mounting bracket on the clockspring (3). 9. Install steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 10. Install upper (1) and lower (2) steering column shrouds,See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 915 11. Install air cleaner fresh air duct (2) and disconnect and isolate negative battery cable at battery, See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Installation. 12. Check operation of all steering column mounted components. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 919 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 920 Knock Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-KNOCK (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal REMOVAL The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Disconnect the negative battery cable. 2. Remove the bolt holding the knock sensor. 3. Remove sensor with electrical connector attached. 4. Disconnect electrical connector from knock sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 923 5. Remove the knock sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 924 Knock Sensor: Service and Repair Knock Sensor - Installation INSTALLATION The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Attach electrical connector to knock sensor. 2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening effects knock sensor performance, possibly causing improper spark control. 3. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 930 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 931 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 932 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 933 Impact Sensor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 935 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 936 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 937 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 938 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way Impact Sensor: Diagrams Left Front Impact Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-FRONT IMPACT-LEFT - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 941 Impact Sensor: Diagrams Left Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 1 - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 942 Impact Sensor: Diagrams Right Front Impact Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-FRONT IMPACT-RIGHT - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 943 Impact Sensor: Diagrams Right Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-RIGHT 1 - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 944 Impact Sensor: Diagrams Left Front Impact Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-FRONT IMPACT-LEFT - (ENGINE COMPARTMENT) 2 WAY Left Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 1 - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 945 Right Front Impact Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-FRONT IMPACT-RIGHT - (ENGINE COMPARTMENT) 2 WAY Right Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-RIGHT 1 - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 946 Left Side Impact Sensor 2 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-LEFT 2 - (BODY) 2 WAY Right Side Impact Sensor 2 (Body) 2 Way Connector - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 947 SENSOR-SIDE IMPACT-RIGHT 2 - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description Impact Sensor: Description and Operation Impact Sensor - Description Front FRONT Two front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front sensor is secured with a screw to the backs of the right and left vertical members of the radiator support within the engine compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side SIDE Four side impact sensors (1) are used on this vehicle when it is equipped with the optional side curtain airbags, two each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a screw to the inner right or left B-pillar ahead of the front seat belt retractor, and the inner quarter panel near the C-pillar beneath the trim within the passenger compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 950 The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 951 Impact Sensor: Description and Operation Impact Sensor - Operation Front FRONT The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the Supplemental Restraint System (SRS) electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the front impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side SIDE The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side Supplemental Restraint System (SRS) electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through the same left or right sensor plus and minus circuits in a series arrangement from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal Impact Sensor: Service and Repair Impact Sensor - Removal Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. NOTE: The front and side impact sensors are interchangeable. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the screw (4) that secures the impact sensor (3) to the of the right or left radiator support vertical member (2). 3. Disconnect the engine compartment wire harness connector (1) from the right or left front impact sensor connector receptacle. 4. Remove the right or left front impact sensor from the engine compartment. Side - B-Pillar SIDE - B-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and side impact sensors are interchangeable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 954 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the trim from the inside of the lower right or left B-pillar (3). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. 4. Remove the screw (1) that secures the side impact sensor (2) to the lower B-pillar. 5. Disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the sensor from the B-pillar. Side - C-Pillar SIDE - C-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and side impact sensors are interchangeable. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the quarter trim panel from the inside of the lower C-pillar (1). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Remove the screw (4) that secures the side impact sensor (3) to the C-pillar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 955 4. Disconnect the body wire harness connector (2) from the sensor (3) connector receptacle. 5. Remove the sensor from the C-pillar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 956 Impact Sensor: Service and Repair Impact Sensor - Installation Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. NOTE: The front and side impact sensors are interchangeable. 1. Position the right or left front impact sensor (3) into the engine compartment. 2. Reconnect the engine compartment wire harness connector (1) to the sensor connector receptacle. 3. Carefully position the sensor onto the back of the right or left radiator support vertical member (2). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the radiator support. 4. Install and tighten the screw (4) that secures the sensor to the back of the support vertical member. Tighten the screw to 8 Nm (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Restraint Systems/Service and Repair. Side - B-Pillar SIDE - B-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 957 NOTE: The front and side impact sensors are interchangeable. 1. Reconnect the body wire harness connector (4) to the side impact sensor (2) connector receptacle. 2. Position the sensor onto the inner B-pillar (3). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the B-pillar. 3. Install and tighten the screw (1) that secures the sensor to the inner B-pillar. Tighten the screw to 8 Nm (70 in. lbs.). 4. Reinstall the lower trim onto the inside of the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation. 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Restraint Systems/Service and Repair. Side - C-Pillar SIDE - C-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and side impact sensors are interchangeable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 958 1. Reconnect the body wire harness connector (2) to the side impact sensor (3) connector receptacle. 2. Position the sensor onto the lower inner C-pillar (1). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the C-pillar. 3. Install and tighten the screw (4) that secures the sensor to the inner C-pillar. Tighten the screw to 8 Nm (70 in. lbs.). 4. Reinstall the quarter trim panel onto the inner lower C-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Restraint Systems/Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 962 Seat Belt Buckle Switch: Diagrams Connector - (BODY) 2 WAY SWITCH-SEAT BELT-DRIVER - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Seat Belt Switch - Description Seat Belt Buckle Switch: Description and Operation Seat Belt Switch - Description DESCRIPTION The seat belt switch (4) is a small, normally open, single pole, single throw, plunger (3) actuated, momentary switch. One seat belt switch is installed on the driver side front seat belt retractor frame (2) over the retractor spool (1). The seat belt switch includes an integral connector that is connected to the vehicle electrical system through a take out and connector of the body wire harness. The seat belt switch cannot be adjusted or repaired and, if ineffective or damaged, the switch unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Seat Belt Switch - Description > Page 965 Seat Belt Buckle Switch: Description and Operation Seat Belt Switch - Operation OPERATION The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The seat belt switch plunger is actuated by the seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half, the switch plunger is extended and closes the seat belt switch sense circuit to ground. Conversely, when the seat belt tip-half webbing is wound onto the retractor spool the switch plunger is depressed, opening the ground path. The EMIC monitors the seat belt switch status, then controls the illumination of the seatbelt indicator and the generation of audible electronic chime tones based upon that input. The seat belt switch receives ground through its connection to the body wire harness from another take out of the body wire harness. An eyelet terminal connector on that ground take out is secured under a ground screw. The seat belt switch is connected in series between ground and the seat belt switch sense input of the EMIC. The seat belt switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Service and Repair > Seat Belt Switch - Removal Seat Belt Buckle Switch: Service and Repair Seat Belt Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt switch unit. The front retractor also includes a seat belt tensioner. If the front seat belt switch is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Restraint Systems/Service and Repair . If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. See: Restraint Systems/Service and Repair . 1. Adjust the front seat to its most forward position for easiest access to the front seat belt lower anchor cover (1) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the driver side seat belt retractor from the lower B-pillar. See: Restraint Systems/Seat Belt Systems/Seat Belt Retractor/Service and Repair/Seat Belt Retractor - Removal. 4. Extract the seat belt webbing (1) from the retractor far enough to eliminate any contact between the seat belt switch plunger (5) and the webbing on the retractor spool. 5. Lift the latch tab (2) integral to the seat belt switch (4) far enough to allow the switch to be pushed off of the retractor frame tie bar (3). 6. Remove the seat belt switch from the retractor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Service and Repair > Seat Belt Switch - Removal > Page 968 Seat Belt Buckle Switch: Service and Repair Seat Belt Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt switch unit. The front retractor also includes a seat belt tensioner. If the front seat belt switch is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Restraint Systems/Service and Repair . If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. See: Restraint Systems/Service and Repair . 1. Extract the seat belt webbing (1) from the retractor far enough to allow clearance between the seat belt switch plunger (5) and the webbing on the retractor spool during switch installation. 2. Position the seat belt switch (4) to the lower edge of the retractor frame tie bar (3) with the plunger oriented toward the retractor spool. 3. Push the switch onto the tie bar until the integral latch feature (2) is fully engaged over the tie bar. 4. Reinstall the driver side seat belt retractor onto the lower B-pillar. See: Restraint Systems/Seat Belt Systems/Seat Belt Retractor/Service and Repair/Seat Belt Retractor - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description Seat Position Sensor: Description and Operation Seat Track Position Sensor - Description DESCRIPTION The seat track position sensor (2) is a Hall Effect-type sensor used on some vehicles. This sensor consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the molded plastic sensor housing. The sensor housing has a mounting slot containing an integral latch feature (1) and slides and latches onto a stamped metal blade-type bracket located on the inboard side of the upper outboard seat adjuster track near the rear of both the passenger and driver front seats. A molded connector receptacle (3) integral to the sensor housing is connected to the vehicle electrical system through a connector and take out of the seat wire harness beneath the front seat cushion frame. The seat track position sensor cannot be adjusted or repaired and, if ineffective or damaged, the entire sensor must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description > Page 973 Seat Position Sensor: Description and Operation Seat Track Position Sensor - Operation OPERATION The seat track position sensor is designed to provide a seat position data input to the Occupant Restraint Controller (ORC) indicating whether the driver or passenger front seat is in a full forward or a not full forward position. The ORC uses this data as an additional logic input for use in determining the appropriate deployment force to be used when deploying the multistage driver side front airbag. The seat track position sensor receives a nominal five volt supply from the ORC. The sensor communicates the seat position by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic Trouble Code (DTC) for any fault that is detected. The ORC then sends messages over the CAN data bus to control the illumination of the airbag indicator in the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The hard wired circuits between the seat track position sensor and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the seat track position sensor or the electronic controls and communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the seat track position sensor or the electronic controls and communication related to seat track position sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal Seat Position Sensor: Service and Repair Seat Track Position Sensor - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Reach under the front seat cushion to access the seat track position sensor (2) on a bracket located on the outboard side near the rear of the upper outboard seat track (3). 3. Using a small screwdriver, hold the latch feature (4) depressed while sliding the connector end of the sensor off of the bracket. 4. Disconnect the seat wire harness connector (1) from the sensor connector receptacle. 5. Remove the sensor from under the front seat. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal > Page 976 Seat Position Sensor: Service and Repair Seat Track Position Sensor - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the front seat cushion to reconnect the seat wire harness connector (1) to the seat track position sensor (2) connector receptacle. Be certain that the latch on the connector is fully engaged. 2. Align the open end of the sensor to the slide tab of the sensor bracket located on the outboard side near the rear of the upper outboard seat track (3). 3. Push the sensor firmly onto the bracket until the latch feature (4) snaps into place with an audible click. 4. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Restraint Systems/Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Driver Seat Track Position Sensor Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Driver Seat Track Position Sensor > Page 981 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Driver Seat Track Position Sensor (Driver Seat) 2 Way Seat Sensor/Switch: Diagrams Driver Seat Track Position Sensor (Driver Seat) 2 Way Connector - (DRIVER SEAT) 2 WAY SENSOR-SEAT TRACK POSITION-DRIVER - (DRIVER SEAT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Driver Seat Track Position Sensor (Driver Seat) 2 Way > Page 984 Seat Sensor/Switch: Diagrams Passenger Seat Track Position Sensor (Passenger Seat) 2 Way Connector - (PASSENGER SEAT) 2 WAY SENSOR-SEAT TRACK POSITION-PASSENGER - (PASSENGER SEAT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Removal REMOVAL WARNING: Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. This will disable the front airbag system. Failure to disconnect the battery could result in accidental front airbag module deployment and possible personal injury.Do not place a non-deployed airbag face down on a hard surface as the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. 1. Remove air cleaner fresh air duct (2) and disconnect and isolate negative battery cable at battery, See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal. 2. Remove upper (1) and lower (2) steering column shrouds,See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 991 3. Remove steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 4. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket integral to the right side of the clockspring (3) on the steering column. 5. Slide the switch away from the clockspring far enough to disengage the slide tab on the bottom of the switch housing from the channel formation in the mounting bracket. Position the multi-function switch (1) aside. 6. Position steering column to the full down position. 7. Position ignition key to the RUN position. 8. Remove screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 9. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and position the SKREEM/WCM (2) back on the lock cylinder housing (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 992 10. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing. Depress the key cylinder retaining tab. 11. Pull key cylinder (3) and key (2) straight out of the lock cylinder housing as one unit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 993 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Installation INSTALLATION 1. Place actuator in the lock cylinder housing to the RUN position (if not already there). 2. Insert key into key cylinder and turn key cylinder to the RUN position. 3. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 4. Slide key cylinder into the lock cylinder housing until key cylinder retaining tab locks the cylinder into place. 5. Rotate key back and forth (OFF to START), then remove and reinstall it, making sure key cylinder and lock cylinder housing operate properly. 6. Slide the ring of SKREEM/WCM (2) over lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 7. Install screw (1) fastening the SKREEM/WCM (2) to lock cylinder housing (3). Tighten screw to 2.5 Nm (22 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 994 8. Install and tighten the screw (2) that secures the mounting tab on the back of the right multi-function switch (1) to the mounting bracket on the clockspring (3). 9. Install steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 10. Install upper (1) and lower (2) steering column shrouds,See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 995 11. Install air cleaner fresh air duct (2) and disconnect and isolate negative battery cable at battery, See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Installation. 12. Check operation of all steering column mounted components. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 999 Neutral Safety Switch: Diagrams Connector (MTX) - (BODY) 3 WAY SWITCH-CLUTCH INTERLOCK (MTX) - (BODY) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The Tire Pressure Monitoring (TPM) system has been optimized for the original equipment tires and wheels. TPM system pressures have been established for the tire size equipped on the vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, or style. Aftermarket wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with TPM, as damage to the sensors may result. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: When installing the valve core, be sure to tighten the core to specifications See: Maintenance/Wheels and Tires/Wheels/Specifications . Overtightening by a little as three or four inch pounds can damage the sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a white outline oval (black center) insignia (3) on the sensor body. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1007 The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by either a solid white oval insignia (3) on the body or. . a solid white oval insignia (3) with 433 printed in the center. The sensors are identical except for the oval insignia. The 433 MHz sensors can either have a black or grey sensor body. CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Sensors may be identified by valve stem cap color. From the factory, 315 MHz sensors have a gray valve stem cap while 433 MHz sensors have a black valve stem cap. Otherwise, once mounted inside a tire and wheel assembly you are not able to visually tell the difference between a 315 MHz and 433 MHz sensor. At that point, the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1008 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1009 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer, or from a transponderSee: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Tire Pressure Monitor Receiver / Transponder/Description and Operation/Tire Pressure Monitoring (TPM) Transponder - Operation. The TPM-RKE Analyzer has the ability to change the sensor's operating mode to PARK MODE and to help diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following operating modes: - SLEEP MODE - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. PARK MODE - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 psi (6.9 kPa) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 BLOCK MODE - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to PARK MODE using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph (24 km/h). In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 10 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to DRIVE MODE. - DRIVE MODE - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). Anytime the vehicle speed drops below 15 mph (24 km/h), the sensor mode will still be in Drive Mode, but will not transmit until the vehicle reaches speeds over 15 mph (24 km/h) once again. If the vehicle has been stationary for more then 20 minutes, the sensor state will transition to Park Mode. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 mph (24 km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The WCM can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1012 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1013 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1014 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the outer and inner tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. 8. Remove the support and lower the vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1015 b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations > Page 1021 Fluid Pressure Sensor/Switch: Diagrams Connector - (BODY) 22 WAY ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH - (BODY) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Speed Sensor, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation DESCRIPTION The Vehicle Speed Sensor (VSS) is a hall effect sensor mounted above the transaxle differential. The sensor is triggered by the ring gear teeth passing below it. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Vehicle Speed Sensor - Removal Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor - Removal REMOVAL 1. Open hood. 2. Remove the air cleaner housing.See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal 3. Disconnect the speed sensor connector. CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 4. Remove speed sensor retaining bolt. 5. Remove speed sensor from transaxle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Vehicle Speed Sensor - Removal > Page 1034 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor - Installation INSTALLATION 1. Using a NEW O-ring, install the speed sensor to the transaxle. 2. Install the bolt and tighten to 7 Nm (60 in. lbs.). 3. Connect speed sensor connector. 4. Install the air cleaner housing.See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Description DESCRIPTION The switch for the rear window defogger (EBL) system (2) is located in the A/C-heater control (1) in the instrument panel center bezel. When the rear window defogger switch is pressed to the On position a request signal is sent to the cabin compartment node (CCN), which sends a message to the totally integrated power module (TIPM) to operate the EBL system. When the high side driver in the TIPM is energized, current is directed to the rear defogger grid lines and to the heated side view mirrors (when equipped) to help clear the glass surfaces of fog or frost. An amber indicator (3) in the rear window defogger switch will illuminate when the EBL system is turned on. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description > Page 1040 Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Operation OPERATION An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the cabin compartment node (CCN), which sends a message to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors, when equipped. NOTE: The EBL system turns off automatically after 10 minutes of initial operation. Each following activation cycle of the EBL system will last 5 minutes. The EBL system will automatically turn off after an initial programmed time interval of about 10 minutes as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 5 minutes. The EBL system will also turn off if the ignition switch is turned to any position other than RUN or by manually pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool. The rear window defogger switch and indicator cannot be adjusted or repaired. The A/C-heater control must be replaced if the rear window defogger switch or indicator is found inoperative or damaged See: Heating and Air Conditioning/Control Assembly/Service and Repair/A/C and Heater Control - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Front Power Window Switch Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Front Power Window Switch > Page 1045 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver Power Window Switch C1 (Left/Right Front Door) 6 Way Power Window Switch: Diagrams Driver Power Window Switch C1 (Left/Right Front Door) 6 Way Connector C1 - (LEFT/RIGHT FRONT DOOR) 6 WAY SWITCH-POWER WINDOW-DRIVER - (LEFT/RIGHT FRONT DOOR) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver Power Window Switch C1 (Left/Right Front Door) 6 Way > Page 1048 Power Window Switch: Diagrams Left Rear Power Window Switch (Left Rear Door) 6 Way Connector - (LEFT REAR DOOR) 6 WAY SWITCH-POWER WINDOW-LEFT REAR - (LEFT REAR DOOR) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver Power Window Switch C1 (Left/Right Front Door) 6 Way > Page 1049 Power Window Switch: Diagrams Passenger Power Window Switch (Left/Right Front Door) 6 Way Connector - (LEFT/RIGHT FRONT DOOR) 6 WAY SWITCH-POWER WINDOW-PASSENGER - (LEFT/RIGHT FRONT DOOR) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver Power Window Switch C1 (Left/Right Front Door) 6 Way > Page 1050 Power Window Switch: Diagrams Right Rear Power Window Switch (Right Rear Door) 6 Way Connector - (RIGHT REAR DOOR) 6 WAY SWITCH-POWER WINDOW-RIGHT REAR - (RIGHT REAR DOOR) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal Power Window Switch: Service and Repair Power Window Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Removal. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal > Page 1053 Power Window Switch: Service and Repair Power Window Switch - Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Installation 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description Wiper Switch: Description and Operation Right Multifunction Switch - Description DESCRIPTION The right (wiper) multi-function switch is located on the right side of the steering column, just below the steering wheel. This switch is the primary control for the front and rear wiper and washer systems. The only visible components of the switch are the control stalk (1), control knob (2) and control sleeve (3) that extend through the steering column shrouds on the right side of the column. The remainder of the switch including its mounting provisions and electrical connection are concealed beneath the shrouds. The switch housing and controls (6) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and is connected by a jumper wire harness (5) directly to the Steering Control Module (SCM), which is internal to the housing (2) of the left multi-function switch (1). The right (wiper) multi-function switch provides the vehicle operator with a control interface for the following wiper and washer system functions: - Continuous Front Wipers - The right multi-function switch control knob provides detent switching for two continuous front wipe modes, low speed or high speed. - Intermittent Front Wipers - The right multi-function switch control knob provides detent switching for the intermittent front wipe mode with five minor detent delay interval positions. - Front Wiper Mist Mode - The right multi-function switch control stalk includes momentary switching of the front wiper motor low speed circuit to provide a mist mode features (sometimes referred to as pulse wipe), which allows the vehicle operator to momentarily operate the front wipers for one or more complete cycles. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description > Page 1059 - Front Washer Mode - The right multi-function switch control stalk provides momentary switching for control of the front washer system operation. - Intermittent Rear Wipe Mode - The right multi-function switch control sleeve provides detent switching for a single fixed interval intermittent rear wiper mode. - Rear Washer Mode - The right multi-function switch control sleeve provides two momentary switch positions for control of rear washer system operation. The right multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description > Page 1060 Wiper Switch: Description and Operation Right Multifunction Switch - Operation OPERATION The right (wiper) multi-function switch uses a combination of resistor multiplexing and conventional switching to control the many functions and features it provides. The switch receives a clean ground from the Steering Control Module (SCM), then provides resistor multiplexed and conventional analog return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic wiper and washer switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the right multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a fail-safe mode of operation for the front and rear wiper systems. The fail-safe mode will maintain the last selected front and rear wiper system operation for the remainder of the current ignition cycle, after which both wiper systems will default to OFF. The right multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Following are descriptions of how the right multi-function switch is operated to control the many front and rear wiper and washer system functions and features it provides: - Front Wiper Control - The control knob on the end of the right multi-function switch control stalk is rotated to one of the two continuous wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The SCM reads the input from the right multi-function switch and sends electronic wiper switch status messages over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Wiper Mist Mode - The front wiper mist mode is requested when the right multi-function switch control stalk is depressed downward towards the floor to a momentary MIST position. The front wiper motor will continue to operate, one complete cycle at a time, for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Washer Control - The right multi-function switch control stalk is pulled rearward towards the steering wheel to a momentary WASH position to activate the washer pump/motor in the front washer mode. The washer pump/motor will continue to operate for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Wiper Control - The rear wiper mode is selected when the right multi-function switch control sleeve is rotated to the fixed interval intermittent rear wipe detent position, or the OFF detent position. The SCM reads the input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Washer Control - The right multi-function switch control sleeve is rotated to one of two momentary WASH positions, either fully forward or fully rearward, to activate the washer pump/motor in the rear washer mode. The washer pump/motor will continue to operate in the rear washer mode until the control sleeve is released. The SCM reads the input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1061 Wiper Switch: Testing and Inspection RIGHT MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. The right multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the Steering Control Module (SCM) or the electronic controls or communication between other modules and devices that provide some features of the front and rear wiper and washer systems. The most reliable, efficient and accurate means to diagnose the SCM or the electronic controls and communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. 1. Remove the right multi-function switch from the integral mounting bracket on the right side of the clockspring. See: Service and Repair/Right Multifunction Switch - Removal. 2. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the three Function Tests tables. For all functions except those of the control stalk the values should be either less than 100 ohms (switch CLOSED) or greater than 1 megohm (switch OPEN). CONTROL STALK FUNCTION TESTS CONTROL KNOB FUNCTION TESTS CONTROL SLEEVE FUNCTION TESTS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1062 3. If the switch fails any of the tests, replace the ineffective right multi-function switch as required. If the switch tests okay, but the switch input to the Steering Control Module (SCM) remains incorrect, be certain to check for a short or open in the jumper harness between the right multi-function switch and the SCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Right Multifunction Switch - Removal Wiper Switch: Service and Repair Right Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket integral to the right side of the clockspring (3) on the steering column. 4. Slide the switch away from the clockspring far enough to disengage the slide tab on the bottom of the switch housing from the channel formation in the mounting bracket. 5. Disconnect the jumper wire harness connector (1) from the connector receptacle on the inboard end of the right multi-function switch (2). 6. Remove the switch from the clockspring (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Right Multifunction Switch - Removal > Page 1065 Wiper Switch: Service and Repair Right Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the right multi-function switch (2) close enough to the mounting bracket (3) integral to the right side of the clockspring to reconnect the jumper wire harness connector (1) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tab on the bottom of the switch housing with the channel integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the back of the right multi-function switch (1) to the mounting bracket on the clockspring (3). 4. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 5. Reconnect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Ride Height Alignment: Specifications Ride Height CURB HEIGHT SPECIFICATIONS - 2.0L GAS ENGINE CURB HEIGHT SPECIFICATIONS - ALL OTHERS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Ride Height > Page 1071 Alignment: Specifications Wheel Alignment WHEEL ALIGNMENT NOTE: All specifications are given in degrees. NOTE: All wheel alignments are to be set with the vehicle at curb height. See: Service and Repair NOTE: Each of the following tables refers to a vehicle equipped with a specific size OEM wheel (except Export). ALL WITH 15 INCH WHEELS ALL WITH 17 INCH WHEELS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Ride Height > Page 1072 ALL WITH 18 INCH WHEELS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Ride Height > Page 1073 SRT4 ALL EXPORT Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Ride Height > Page 1074 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1075 Alignment: Description and Operation DESCRIPTION Vehicle wheel alignment is the positioning of all interrelated front and rear suspension angles. These angles affect the handling and steering of the vehicle when it is in motion. Proper wheel alignment is essential for efficient steering, good directional stability, and proper tire wear. The method of checking a vehicle's front and rear wheel alignment varies depending on the manufacturer and type of equipment used. The manufacturer's instructions should always be followed to ensure accuracy of the alignment, except when Chrysler Corporation's wheel alignment specifications differ. On this vehicle, the suspension angles that can be adjusted are as follows: Front - Camber (with cradle shift or service adjustment bolt package) - Caster (limited adjustment with cradle shift) - Toe Rear - Toe Check the wheel alignment and make all wheel alignment adjustments with the vehicle standing at its proper curb height specification. Curb height is the normal riding height of the vehicle. It is measured from a certain point on the vehicle to the ground or a designated area while the vehicle is sitting on a flat, level surface. Refer to Curb Height Measurement for additional information. See: Service and Repair/Curb Height Measurement Typical wheel alignment angles and measurements are described in the following paragraphs. CAMBER Camber is the inward or outward tilt of the top of the tire and wheel assembly. Inward tilt (2) is known as negative camber. Outward tilt (1) is known as Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1076 positive camber. Camber is measured in degrees of angle relative to a true vertical line. Camber is a tire wearing angle. - Excessive negative camber will cause tread wear at the inside of the tire. - Excessive positive camber will cause tread wear on the outside of the tire. CROSS CAMBER Cross camber is the difference between left and right camber. To achieve the cross camber reading, subtract the right side camber reading from the left. For example, if the left camber is -0.7° and the right camber is -0.5°, the cross camber would be -0.2° (-0.7 - (-0.5) = -0.7 + 0.5 = -0.2). CASTER Caster is the forward or rearward tilt of the steering knuckle in reference to the position of the upper and lower ball joints. Caster is measured in degrees of angle relative to a true vertical center line. This line is viewed from the side of the tire and wheel assembly. - Forward tilt (upper ball joint ahead of lower) results in a negative caster angle. - Rearward tilt (upper ball joint trailing lower) results in a positive caster angle. Although caster does not affect tire wear, a caster imbalance between the two front wheels may cause the vehicle to lead to the side with the least positive caster. CROSS CASTER Cross caster is the difference between left and right caster. To achieve the cross caster reading, subtract the right side caster reading from the left. For example, if the left caster is 2.5° and the right caster is 2.7°, the cross caster would be -0.2° (2.5 - 2.7 = -0.2). TOE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1077 Toe is the inward or outward angle of the wheels as viewed from above the vehicle. - Toe-in (1) is produced when the front edges of the wheels on the same axle are closer together than the rear edges. - Toe-out (2) is produced when the front edges of the wheels on the same axle are farther apart than the rear edges. Toe-in and toe-out can occur at the front wheels and the rear wheels. Toe is measured in degrees or inches. The measurement identifies the amount that the front of the wheels point inward (toe-in) or outward (toe-out). Toe is measured at the spindle height. Zero toe means the front and rear edges of the wheels on the same axle are equal distant. TOE-OUT ON TURNS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1078 Toe-out on turns (1), sometimes referred to as Ackerman Steering, is the relative positioning of the front wheels while steering through a turn. This compensates for each front wheel's turning radius. As the vehicle encounters a turn, the outboard wheel must travel in a larger radius circle than the inboard wheel. The steering system is designed to make each wheel follow its particular radius circle. To accomplish this, the front wheels must progressively toe outward as the steering is turned from center. This eliminates tire scrubbing and undue tire wear when steering a vehicle through a turn. DYNAMIC TOE PATTERN Dynamic toe pattern is the inward and outward toe movement of the front and rear tires through the suspension's jounce and rebound travel. As the vehicle's suspension moves up and down, the toe pattern varies. Toe pattern is critical in controlling the directional stability of the vehicle while in motion. Front and rear dynamic toe pattern is preset by the factory at the time the vehicle is assembled. It is not necessary to check or adjust front or rear dynamic toe pattern when doing a normal wheel alignment. The only time dynamic toe pattern needs to be checked or adjusted is if the frame of the vehicle has been damaged. STEERING AXIS INCLINATION (S.A.I.) Steering axis inclination (1) is the angle between a true vertical line starting at the center of the tire at the road contact point and a line drawn through the center of the upper ball joint (or strut) and the lower ball joint. S.A.I. is built into the vehicle and is not an adjustable angle. If S.A.I. is not within specifications, a bent or damaged suspension component may be the cause. INCLUDED ANGLE (I.A.) Included angle (3) is the sum of the S.A.I. angle (1) plus or minus the camber angle (2), depending on whether or not the wheel has positive or negative camber. If camber is positive, add the camber angle to the S.A.I angle. If camber is negative, subtract the camber angle from the S.A.I. angle. Included angle is not adjustable, but can be used to diagnose a frame misalignment or bent suspension component (spindle, strut). THRUST ANGLE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1079 Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle's center line. The presence of negative or positive thrust angle causes the rear tires to track improperly to the left or right of the front tires (dog tracking). - Negative thrust angle means the rear tires are tracking to the left of the front tires. - Positive thrust angle means the rear tires are tracking to the right of the front tires. Improper tracking can cause undue tire wear, a lead or pull and a crooked steering wheel. Excessive thrust angle can usually be corrected by adjusting the rear wheel toe so that each wheel has one-half of the total toe measurement. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Alignment: Service and Repair Wheel Alignment WHEEL ALIGNMENT PRE-WHEEL ALIGNMENT INSPECTION Before any attempt is made to change or correct the wheel alignment, the following inspection and necessary corrections must be made to the vehicle to ensure proper alignment. 1. Verify the fuel tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. The passenger and luggage compartments of the vehicle should be free of any load that is not factory equipment. 3. Check the tires on the vehicle. The tires are to be inflated to the recommended air pressure. All tires must be the same size and in good condition with approximately the same tread wear. 4. Check the front tire and wheel assemblies for excessive radial runout. 5. Inspect all suspension component fasteners for looseness and proper torque. 6. Inspect the lower front ball joints and all steering linkage for looseness and any sign of wear or damage. 7. Inspect the rubber bushings on all the suspension components for signs of wear or deterioration. If any bushings show signs of wear or deterioration, they should be replaced prior to aligning the vehicle. 8. Check vehicle curb height to verify it is within specifications. See: WHEEL ALIGNMENT SETUP 1. Position the vehicle on an alignment rack. 2. Install all required alignment equipment on the vehicle, per the alignment equipment manufacturer's instructions. On this vehicle, a four-wheel alignment is recommended. NOTE: Prior to reading the vehicle's alignment readouts, the front and rear of vehicle should be jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing each end of vehicle an equal number of times. The bumper should always be released when vehicle is at the bottom of the jounce cycle. 3. Read the vehicle's current front and rear alignment settings. Compare the vehicle's current alignment settings to the vehicle specifications for camber, caster and toe-in. See: Specifications/Wheel Alignment REAR CAMBER Rear camber settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as Net Build. The result is no required adjustment of camber after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, rear camber is not considered an adjustable angle. CAUTION: Do not attempt to adjust the vehicle's wheel alignment by heating or bending any of the suspension components. FRONT CAMBER AND CASTER Front camber and caster settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as Net Build. The result is no required adjustment of camber and caster after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, caster and camber are not normally considered adjustable angles but some adjustment can be made. Camber and caster should be checked to ensure they meet vehicle specifications. See: Specifications/Wheel Alignment If individual front camber or caster is found not to meet alignment specifications, each can be adjusted by shifting the front crossmember or by using an available service adjustment bolt package. If an adjustment bolt package installation is necessary, inspect the suspension components for any signs of damage or bending first. CAUTION: Do not attempt to adjust the vehicle's wheel alignment by heating or bending any of the suspension components. ADJUSTMENT BY SHIFTING CROSSMEMBER CAUTION: Always use care when shifting crossmember to avoid damaging other components on the vehicle. 1. Loosen the four bolts fastening the front crossmember to the frame just enough to allow movement of the crossmember. See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Removal 2. Loosen the bolts fastening the fore/aft crossmember to the frame just enough to allow movement of the crossmember. See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Removal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1082 CAUTION: When shifting the front crossmember, keep in mind that the front and rear engine mounts are attached to the front crossmember and fore/aft crossmember and should be inspected following the crossmember shift to make sure they are properly aligned. 3. Shift front crossmember as necessary (See following tables) to bring camber or caster into specifications. When shifting crossmember, use care not to move other angles (camber or caster) that are within specifications, out of specifications. 4. Tighten all previously loosened fasteners (bolts) securing the crossmember to the vehicle to specifications. See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Installation 5. Jounce the rear, then front of the vehicle an equal amount of times. 6. Measure camber and caster. If camber and caster are within specifications, proceed to TOE. If camber cannot be brought into specifications, perform the CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION below. CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION The camber adjustment bolt package contains new bolts and nuts for attaching the strut clevis bracket to the steering knuckle. The bolts contained in the package are slightly undersize allowing for movement between the strut clevis bracket and the steering knuckle. The movement allowed by the undersize bolts provide approximately two degrees of camber adjustment per side of the vehicle. To install and adjust the camber adjustment bolt package, follow the procedure below. 1. Raise the vehicle until its tires are not supporting the weight of the vehicle. See: Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the front tire and wheel assembly (1). CAUTION: The strut clevis-to-knuckle attaching bolt shanks are serrated and must not be turned during removal. Remove the nuts while holding the bolts stationary, then tap the bolts out using a punch. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1083 3. Remove the original upper bolt (1) and nut (3) attaching the strut clevis bracket (2) to the knuckle (5). 4. Install a bolt from the adjustment package into the hole where the original bolt was removed. Install the bolt as indicated. 5. Install a nut provided in adjustment package on the replacement bolt. Tighten the nut until it's snug, but still allows the knuckle to slide in the clevis bracket. 6. Remove the original lower bolt (6) and nut (4) attaching the strut clevis bracket (2) to the knuckle (5). 7. Install a bolt from the adjustment package into the bottom hole of the strut clevis bracket. Install the bolt as indicated. 8. Install a nut provided in adjustment package on the replacement bolt. Tighten the nut until it's snug, but still allows the knuckle to slide in the clevis bracket. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1084 9. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 10. Perform the above procedure to opposite strut as required. 11. Lower the vehicle and jounce the front and rear of the vehicle. 12. Adjust the front camber to the preferred setting by pushing or pulling on the top of the tire. When camber is set to specifications, tighten the upper and lower strut clevis-to-knuckle attaching bolt nuts (3, 4) enough to hold the adjustment. Again jounce the front and rear of the vehicle, then verify the camber settings. 13. Tighten the front strut clevis-to-knuckle attaching bolt nuts (3, 4) to 110 Nm (81 ft. lbs.). 14. Once camber is within specifications, adjust toe to meet the preferred specification setting. Refer to FRONT TOE within this wheel alignment service procedure. TOE 1. Center the steering wheel and lock it in place using a steering wheel clamp. NOTE: When setting toe, make sure to set rear toe to the preferred specifications before setting front toe to the preferred specifications REAR TOE NOTE: Perform the following at each rear wheel as necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1085 1. While holding the cam bolt head (3) stationary, loosen the toe link mounting cam bolt nut (1). 2. Rotate the cam bolt head (3) left or right until the rear wheel toe for that rear wheel is set to the preferred specification. See: Specifications/Wheel Alignment 3. While holding the cam bolt head (3) stationary, tighten the toe link mounting cam bolt nut (1) to 25 Nm (18 ft. lbs.). FRONT TOE NOTE: Perform the following at each front wheel as necessary. CAUTION: Do not twist the inner tie rod-to-steering gear boot (bellows) while turning the inner tie rod during front toe adjustment. It may be necessary to remove the clamp where the boot meets the inner tie rod. 1. Loosen the tie rod adjusting jam nut (1). Grasp the inner tie rod (3) and rotate it one way or the other until the front wheel toe is set to the preferred specification. See: Specifications/Wheel Alignment 2. Tighten the tie rod adjusting jam nut to of 75 Nm (55 ft. lbs.). 3. Make sure the inner tie rod-to-steering gear boot is not twisted. If removed, reinstall the clamp where the boot meets the inner tie rod. 4. Remove the steering wheel clamp. 5. Remove the alignment equipment. 6. Road test the vehicle to verify the steering wheel is straight and the vehicle does not pull or wander. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1086 Alignment: Service and Repair Curb Height Measurement CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. NOTE: Prior to reading the curb height measurement, the front and rear of the vehicle must be jounced to settle the suspension. Induce jounce by pushing down on the center of the bumper (fascia), using care not to damage the vehicle, moving the vehicle up and down, gradually increasing the suspension travel with each stroke. Release the bumper at the bottom of each stroke, repeating this action several times. Perform this to both front and rear suspensions an equal amount of times. Measure curb height as follows: 1. Jounce the vehicle. Refer to above note. NOTE: On some vehicles it may be necessary to remove an engine belly pan in order to gain access to the lower control arm pivot bolt. 2. FRONT - On each side of the vehicle, measure the distance (2) from the lower control arm rear (vertical) pivot bolt head (1) to the floor or alignment rack/lift runway surface. It may be necessary to measure to the bottom of a straight edge (3), placed from lift runway to runway, to get an accurate measurement. 3. REAR - On each side of the vehicle, measure the distance (2) from the center of the outboard trailing arm-to-body mounting bolt (1) to the floor or Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment > Page 1087 alignment rack/lift runway surface. 4. Compare the measurements to specifications listed in the following CURB HEIGHT SPECIFICATIONS chart. Maximum left-to-right differential is not to exceed 12.5 mm (0.5 in.). 5. If curb height is found to be out of specification and there is no sign of excessive body damage, curb height can be changed by replacing the applicable spring with a spring offering a different check load. See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Strut / Shock/Removal CURB HEIGHT SPECIFICATIONS - 2.0L GAS ENGINE CURB HEIGHT SPECIFICATIONS - ALL OTHERS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System Fuel Pressure: Testing and Inspection Checking the Fuel Delivery System CHECKING THE FUEL DELIVERY SYSTEM For a complete wiring diagram, refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. CHECKING THE FUEL PUMP OPERATION 1. Turn the ignition on. NOTE: Diagnose and repair any fuel pump control circuit or relay DTCs before continuing with this test. 2. With a scan tool, actuate the fuel pump control to ON (100%). NOTE: It may be necessary to use a mechanics stethoscope in the next step. 3. Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly, without excessive noise. If necessary, compare to a known good vehicle of similar year, make, and model. NOTE: If the pump has excessive noise or grinding, the pump should be replaced. CAUTION: Stop all actuation tests before continuing. Is the fuel pump operating when actuated? Yes - Go To 2 No - Go To 7 2. CHECKING THE FUEL PRESSURE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Install a fuel pressure gauge on the fuel rail. 3. Turn the ignition on. 4. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: Non SRT fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). CAUTION: Stop all actuation tests before continuing. Select the conclusion that best matches the result of the test: Fuel pressure is within the stated specification - Test complete. Fuel pressure is below the stated specification - Go To 3 Fuel pressure is above the stated specification - Replace the fuel filter/pressure regulator. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 3. RESTRICTED FUEL SUPPLY LINE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1094 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. 3. Install special 5/16 fuel line adapter tool #6539 between disconnected fuel line and the fuel pump module. 4. Attach a fuel pressure test gauge to the T fitting on tool #6539. 5. Turn the ignition on. 6. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: Non SRT fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). CAUTION: Stop all actuation tests before proceeding. Is the fuel pressure within specification? Yes - Repair or replace fuel supply line as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 4 4. SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes - Go To 5 No - Go To 6 5. FUEL TANK SIPHON HOSE OR FUEL LINE RESTRICTED OR DAMAGED 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Gain access to the fuel pump module and the fuel tank module. 3. Inspect the fuel line and siphon hose between the fuel pump module and the fuel tank module. Look for disconnected or damaged lines and hoses. 4. Inspect the fuel pressure regulator for damage or a condition that might cause a fuel flow problem. Make sure that it is seated in the module properly. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 6 6. FUEL PUMP INLET STRAINER 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1095 WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Remove the fuel pump module and inspect the fuel inlet strainer for damage or a condition that might cause a fuel flow problem. Were any problems found? Yes - Replace the Fuel Pump Inlet Strainer. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. 7. FUEL PUMP GROUND CIRCUIT OPEN OR HIGH RESISTANCE 1. Turn the ignition off. 2. Disconnect the Fuel Pump Module harness connector. 3. Using a 12-volt test light connected to 12 volts, check the Fuel Pump Motor Ground circuit at the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Repair the Fuel Pump Ground circuit for an open circuit or high resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1096 Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down FUEL PRESSURE LEAK DOWN For a complete wiring diagram, refer to the Wiring Information. See: Diagrams/Electrical Diagrams WARNING: Follow these safety precautions to reduce the risk of fire and serious possible serious or fatal injury when performing this test procedure. Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. Use extreme caution when connecting and disconnecting fuel lines. - Considerable fuel leakage may occur when servicing the fuel system. Wear protective eye wear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair / replace as necessary. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1097 WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from Gas and Diesel Fuel Pressure/Decay Tester 8978. Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly Fuel Inlet Hose 8978-1 (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect the Reservoir Assembly 534960 (4) to the Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1098 - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 2. Turn the ignition on, wait five seconds, turn the ignition off and then wait 1 minute before proceeding. 3. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT-4 fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the Checking The Fuel Delivery System diagnostic procedure as directed. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System 5. CHECK FUEL DELIVERY SYSTEM FOR LEAK DOWN WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Close the Fuel System Isolation Valve (1) and then wait five minutes before proceeding. 2. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge (1) - Replace the fuel pump module. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Yes - On Fuel Outlet Gauge (2) - Replace the leaking fuel injector(s). - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - If directed here by another test, return to that test. Otherwise, test complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal Air Filter Element: Service and Repair Air Cleaner - Removal REMOVAL 1. Turn lock retainers (5) and remove fresh air inlet (2) from air cleaner housing (1). 2. Disconnect intake air temperature sensor connector (4). 3. Remove air inlet tube (5) from air cleaner housing (1). 4. Unfasten clasps (2) on sides of air cleaner housing cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 1104 5. Pull air cleaner cover (1) aside. 6. Remove filter element (3). 7. If necessary, clean the inside of the air cleaner housing (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 1105 Air Filter Element: Service and Repair Air Cleaner - Installation INSTALLATION 1. Install new filter element. 2. Place cover over air cleaner housing. Snap clasps (2) in place. 3. Install air inlet tube (5). 4. Connect intake air temperature sensor connector (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 1106 5. Install fresh air inlet (2) on air cleaner housing (1) and lock retainers (5). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove lower rear seat cushion. 2. Remove the fuel pump module cover. 3. Disconnect the electrical connector for fuel pump module. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. Turn ignition key to OFF position. 7. Disconnect negative battery cable. 8. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory. The scan tool must be used to erase a DTC. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications FIRING ORDER 1.8, 2.0, 2.4L The firing order is 1-3-4-2. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications Spark Plug: Specifications Spark Plug Specifications SPARK PLUGS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications > Page 1118 Spark Plug: Specifications Torque SPARK PLUG Spark Plugs.......................................................................................................................................... ........................................................27 Nm (20 ft. lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1119 Spark Plug: Application and ID Spark Plug Type................................................................................................................................... ....................................................................ZFR5F-11 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal Spark Plug: Service and Repair Spark Plug - Removal REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the electrical connectors from ignition coils. 3. Remove the ignition coil mounting bolt. 4. Twist the ignition coil then pull straight up. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 1122 5. Remove the spark plug using a quality socket with a rubber or foam insert. 6. Inspect the spark plug condition. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 1123 Spark Plug: Service and Repair Spark Plug - Installation INSTALLATION CAUTION: Handle the spark plugs with care. Do not drop or force the spark plugs into the wells, damage to the electrodes and/or porcelain body may occur. Always start each spark plug by hand in order to avoid cross-threading the spark plug in the cylinder head. Always tighten spark plugs to the specified torque. Too much or not enough torque will cause damage to the cylinder head and/or spark plug and may lead to poor engine performance. 1. Install each spark plug to the cylinder head. Tighten spark plugs to 27 Nm (20 ft. lbs.). 2. Install ignition coil onto spark plug. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 1124 3. Install ignition coil mounting bolt. Tighten to 9 Nm (79.5 in. lbs.). 4. Connect ignition coil electrical connectors. 5. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION CHECK Compression Pressure ............................................................................................................................................................. 1172-1551 kPa (170-225 psi) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1128 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove engine cover. 4. Disconnect coil electrical connectors and remove coils. 5. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators such as fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 6. Disconnect injector electrical connectors. 7. Insert compression gauge adaptor 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer CH7059 with cable adaptors to the DRBIII(R). For Special Tool identification, . See: Engine, Cooling and Exhaust/Engine/Tools and Equipment 8. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. 9. Repeat the previous step for all remaining cylinders. 10. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 11. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 12. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Lash Intake.................................................................................................................................................... ..............................0.17 - 0.23 mm (0.006 - 0.009 in.) Exhaust............................................................ ...................................................................................................................0.27 - 0.33 mm (0.010 0.012 in.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1132 Valve Clearance: Adjustments MEASURING VALVE LASH NOTE: The engine must be cold to measure valve lash. 1. Remove engine cover. 2. Remove cylinder head coverSee: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal. 3. Rotate camshaft so lobes are vertical (1). 4. Check clearance using feeler gauges. 5. Repeat for all tappets and record readings. 6. If clearance was too small, refer to the Clearance too Small procedure. Clearance too Small. 7. If clearance was too large, refer to the Clearance too Large procedure. Clearance too Large. Clearance too Small Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1133 1. Remove camshaftsSee: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Removal. 2. Specification - clearance = change. 3. Decrease tappet thickness by change figure. 4. Install camshafts See: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Installation. 5. Verify that valve lash is correct. Clearance too Large 1. Remove camshaftsSee: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Removal. 2. Clearance - specification = change. 3. Increase tappet thickness by change figure. 4. Install camshaftsSee: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Installation. 5. Verify that valve lash is correct. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation Drive Belt: Description and Operation GAS ENGINE The accessory drive belt (2) is a serpentine type belt that is driven by the crankshaft pulley (6). The belt drives the A/C compressor, generator (3), power steering pump (1) and water pump (7). Belt tension is maintained by an automatic belt tensioner (8). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 1137 Drive Belt: Testing and Inspection ACCESSORY DRIVE BELT VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (1), are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) (2) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for contamination, alignment, glazing, or excessive end play. ACCESSORY DRIVE BELT DIAGNOSIS CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 1138 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures Drive Belt: Procedures CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures > Page 1141 Drive Belt: Removal and Replacement Serpentine Accessory Drive Belt - Removal GAS ENGINE 1. Using a wrench, rotate accessory drive belt tensioner (8) counterclockwise until accessory drive belt (2) can be removed from pulleys (5 and 9). 2. Remove accessory drive belt (2). Serpentine Accessory Drive Belt - Installation GAS ENGINE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures > Page 1142 NOTE: When installing drive belt on the pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulley grooves. 1. Install the accessory drive belt (2) around all the pulleys except for the generator pulley (3). 2. Using a wrench, rotate accessory drive belt tensioner (8) counterclockwise until accessory drive belt (2) can be installed on the generator pulley (3). Release spring tension onto accessory drive belt (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal Air Filter Element: Service and Repair Air Cleaner - Removal REMOVAL 1. Turn lock retainers (5) and remove fresh air inlet (2) from air cleaner housing (1). 2. Disconnect intake air temperature sensor connector (4). 3. Remove air inlet tube (5) from air cleaner housing (1). 4. Unfasten clasps (2) on sides of air cleaner housing cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 1149 5. Pull air cleaner cover (1) aside. 6. Remove filter element (3). 7. If necessary, clean the inside of the air cleaner housing (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 1150 Air Filter Element: Service and Repair Air Cleaner - Installation INSTALLATION 1. Install new filter element. 2. Place cover over air cleaner housing. Snap clasps (2) in place. 3. Install air inlet tube (5). 4. Connect intake air temperature sensor connector (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 1151 5. Install fresh air inlet (2) on air cleaner housing (1) and lock retainers (5). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Description and Operation Cabin Air Filter: Description and Operation DESCRIPTION Some models are equipped with a particulate air filter (1) that helps purify the outside air entering the HVAC housing. The filter is mounted in the passenger compartment, behind the glove box bin. The filter should be replaced at least once a year or every 24,000 km (15,000 miles) and checked if heating-A/C system performance seems lower than expected. The particulate air filter is labeled with an arrow (2) to indicate the direction of air flow through the filter. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Procedures Cabin Air Filter: Procedures REMOVAL NOTE:LHD model shown in illustrations. RHD model similar. NOTE:Illustration shown with instrument panel removed for clarity. 1. Remove the glove box bin. 2. Disengage the two retaining tabs (1) that secure the particulate air filter cover (2) to the passenger side of the HVAC housing (3) and remove the cover. 3. Remove the particulate air filter (1) from the HVAC housing (2) by pulling the filter element straight out of the housing. INSTALL NOTE:The particulate air filter is labeled with an arrow to indicate air flow direction through the filter. Make sure to properly install the particulate air filter. Failure to properly install the filter will result in the need to replace the filter sooner than required by design. NOTE:LHD model shown in illustrations. RHD model similar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 1157 1. Install the particulate air filter (1) into the filter opening in the HVAC housing (2). Insert the particulate air filter directly into the housing with the arrow on the filter pointing to the floor. 2. Position the particulate air filter cover (2) to the HVAC housing (3) and engage the two retaining tabs (1) that secure the cover to the housing. Make sure the retaining tabs are fully engaged. 3. Install the glove box bin Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 1158 Cabin Air Filter: Removal and Replacement Particulate Air Filter - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: Always make sure the A/C-heater system is turned off and that the ignition switch is in the OFF position prior to servicing the particulate air filter. Never place fingers or other objects into the filter opening of the HVAC housing. Failure to follow this warning may result in serious injury. NOTE: LHD model shown in illustrations. RHD model similar. NOTE: Illustration shown with instrument panel removed for clarity. 1. Remove the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Removal. 2. Disengage the two retaining tabs (1) that secure the particulate air filter cover (2) to the passenger side of the HVAC housing (3) and remove the cover. 3. Remove the particulate air filter (1) from the HVAC housing (2) by pulling the filter element straight out of the housing. Particulate Air Filter - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 1159 INSTALLATION NOTE: The particulate air filter is labeled with an arrow to indicate air flow direction through the filter. Make sure to properly install the particulate air filter. Failure to properly install the filter will result in the need to replace the filter sooner than required by design. NOTE: LHD model shown in illustrations. RHD model similar. 1. Install the particulate air filter (1) into the filter opening in the HVAC housing (2). Insert the particulate air filter directly into the housing with the arrow on the filter pointing to the floor. 2. Position the particulate air filter cover (2) to the HVAC housing (3) and engage the two retaining tabs (1) that secure the cover to the housing. Make sure the retaining tabs are fully engaged. 3. Install the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - CVT > Component Information > Service and Repair > Transmission Filter Fluid Filter - CVT: Service and Repair Transmission Filter FLUID AND STRAINER SERVICE 1. Remove the bolts holding the oil pan (1) to the transaxle case. 2. Remove the oil pan from the transaxle case. 3. Remove the oil pan gasket (1) from the transaxle case. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - CVT > Component Information > Service and Repair > Transmission Filter > Page 1164 4. Remove the bolts holding the oil strainer (1) to the valve body. 5. Remove the oil strainer. 6. Remove and discard the oil strainer o-ring. CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring. 7. Install the new o-ring (1) onto the new oil strainer. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - CVT > Component Information > Service and Repair > Transmission Filter > Page 1165 8. Install the new oil strainer (1) onto the control valve assembly. Install and tighten the mounting bolts to 8 Nm (70 in. lbs.). CAUTION: Do not re-use the oil pan gasket. Remove any moisture, oil, and used gasket material from the surface where the new gasket is to be installed. When installing the oil pan gasket, align the dowel pin with the dowel pin hole in the oil pan gasket. 9. Install the oil pan gasket (1) onto the transaxle case. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - CVT > Component Information > Service and Repair > Transmission Filter > Page 1166 CAUTION: When installing the oil pan, align the dowel pin of the transaxle case with the dowel pin hole of the oil pan. 10. Install the oil pan on the transaxle case (1). Install and tighten the mounting bolts to 8 Nm (70 in.lbs.). NOTE: Only transmission fluid of the type labeled Mopar(R) CVTF+4 (Automatic Transmission Fluid) should be used in this transaxle. 11. Check the oil level See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Service and Repair/Procedures/Check Oil Level Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - CVT > Component Information > Service and Repair > Transmission Filter > Page 1167 Fluid Filter - CVT: Service and Repair Transmission Cooler Filter Removal REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the left front tire. 3. Remove the left front splash shield. 4. Drain the coolant. 5. Remove the transmission lines (2) at the cooler (3). 6. Remove the coolant lines (1) at the cooler. 7. Remove the mounting bolts at the cooler. 8. Remove the cooler from the transmission. 9. Remove the fluid filter (1). Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - CVT > Component Information > Service and Repair > Transmission Filter > Page 1168 CAUTION: Apply CVT fluid on the seal part when installing the CVT fluid filter. 1. Install the CVT fluid filter (1) into the transaxle case. CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring. 2. Install the new o-ring (1) onto the CVT fluid filter. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - CVT > Component Information > Service and Repair > Transmission Filter > Page 1169 3. Install the CVT fluid cooler onto the transaxle case. 4. Install and tighten the mounting bolts to 4 Nm (37 in.lbs.). 5. Install the coolant lines (1) at the cooler. 6. Install the transmission lines (2) at the cooler (3). 7. Install the left front splash shield. 8. Install the left front tire. 9. Lower the hoist. 10. Top off coolant See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 11. Top off transmission fluid . See: Fluids/Fluid - CVT/Service and Repair/Transmission Fill Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove lower rear seat cushion. 2. Remove the fuel pump module cover. 3. Disconnect the electrical connector for fuel pump module. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. Turn ignition key to OFF position. 7. Disconnect negative battery cable. 8. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory. The scan tool must be used to erase a DTC. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Procedures Oil Filter: Procedures ENGINE OIL AND FILTER CHANGE WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. Change engine oil at mileage and time intervals described in the Maintenance Schedule See: . 1. Run engine until achieving normal operating temperature. 2. Position the vehicle on a level surface and turn engine off. 3. Remove oil fill cap. 4. Raise vehicle on hoist. 5. Place a suitable oil collecting container under oil pan drain plug (2). 6. Remove oil pan drain plug (2) or and allow oil to drain into collecting container. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 7. Remove oil filter (1) See: Removal and Replacement/Engine Oil Filter - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Procedures > Page 1178 8. Install oil pan drain plug (2) and tighten drain plug to 28 Nm (20 ft. lbs.). 9. Install new oil filter (1)See: Removal and Replacement/Engine Oil Filter - Installation. 10. Lower vehicle and fill crankcase with specified type and amount of engine oil and . 11. Install oil fill cap. 12. Start engine and inspect for leaks. 13. Stop engine and inspect oil level. OIL FILTER SPECIFICATION All engines are equipped with a high quality full-flow, disposable type oil filter. Replace oil filter with a Mopar(R) or the equivalent. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING listed above. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Procedures > Page 1179 Oil Filter: Removal and Replacement Engine Oil Filter - Removal REMOVAL CAUTION: When servicing the oil filter, avoid deforming the filter can by installing the remove/install tool band strap against the can to base lock seam. The lock seam joining the can to the base is reinforced by the base plate. 1. Using a suitable filter wrench, turn oil filter (1) counterclockwise to remove. Engine Oil Filter - Installation INSTALLATION 1. Clean and check filter mounting surface. The surface must be smooth, flat and free of debris or pieces of gasket. 2. Lubricate new oil filter gasket. 3. Screw oil filter (1) on until the gasket contacts base. Tighten to 14 Nm (11 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Water Pump Inlet Tube - Removal Coolant Line/Hose: Service and Repair Water Pump Inlet Tube - Removal REMOVAL The water pump inlet tube (2) connects the water pump to the coolant adapter. This tube is sealed by an O-ring and held in place by fasteners to the water pump housing. 1. Drain cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 2. Remove the coolant adapter and secondary thermostat See: Engine, Cooling and Exhaust/Cooling System/Thermostat/Service and Repair/Engine Coolant Thermostat - Removal. 3. Raise and support vehicle. 4. Remove inlet tube mounting nuts (1). 5. Remove inlet tube (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Water Pump Inlet Tube - Removal > Page 1185 Coolant Line/Hose: Service and Repair Water Pump Inlet Tube - Installation INSTALLATION 1. Inspect the O-ring for damage before installing the tube. Replace O-ring as necessary. 2. Lubricate O-rings with soapy water. 3. Install new water inlet gasket between tube and water pump housing (2). 4. Position water pump inlet tube (3) on water pump housing (2). Hand tighten nuts to aide in tube alignment. 5. Install secondary thermostat and coolant adapter See: Engine, Cooling and Exhaust/Cooling System/Thermostat/Service and Repair/Engine Coolant Thermostat - Installation. 6. Tighten coolant tube nuts (1) to 24 Nm (212 in. lbs.). 7. Fill cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description Hose/Line HVAC: Description and Operation A/C Discharge Line - Description DESCRIPTION NOTE: Typical A/C discharge line shown. The A/C discharge line (1) is the refrigerant line that carries refrigerant from the A/C compressor to the A/C condenser and includes the high side service port (2) and a fitting (3) for the A/C pressure transducer (4). CAUTION: If replacing the A/C discharge line, be sure to use the discharge line designed for the A/C compressor in the vehicle. If replacing the 6SEU16 compressor, be sure to use the latest level of A/C discharge line during replacement. Failure to use the correct A/C discharge line could result in possible discharge line and/or compressor damage. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C discharge line has no serviceable parts except for the metal gaskets (5) and rubber O-ring seals (6) and the high side service port valve core. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C discharge line is disconnected. The A/C discharge line cannot be repaired and must be replaced if leaking or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 1190 Hose/Line HVAC: Description and Operation A/C Liquid Line - Description DESCRIPTION The A/C liquid line (1) is the refrigerant line that carries refrigerant from the A/C condenser to the A/C evaporator. The A/C liquid line contains the low side service port (2) and the variable A/C orifice tube. The A/C liquid line is only serviced as an assembly with the upper A/C suction line (3). NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C liquid/suction line assembly has no serviceable parts except for the metal gaskets (4), rubber O-ring seals (5) and the low side service port valve core. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C liquid/suction line assembly is removed. The A/C liquid/suction line assembly cannot be repaired and must be replaced if found to be leaking or damaged, or if an internal failure of the A/C compressor has occurred. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 1191 Hose/Line HVAC: Description and Operation A/C Suction Line - Description DESCRIPTION The A/C suction line is serviced in two sections. The upper section of the A/C suction line (1) is the refrigerant line that carries refrigerant from the A/C evaporator to the A/C accumulator. The lower section of the A/C suction line (2) carries refrigerant from the A/C accumulator to the A/C compressor. The upper portion of the A/C suction line is only serviced as an assembly with the A/C liquid line (5). NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The lower A/C suction line and the A/C liquid/suction line assembly has no serviceable parts except for the rubber O-ring seals (3), metal gaskets (4) and the low side service port valve core. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the lower A/C suction line and/or the A/C liquid/suction line assembly is disconnected. The lower A/C suction line and the A/C liquid/suction line assembly cannot be repaired and must be replaced leaking or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal Hose/Line HVAC: Service and Repair A/C Discharge Line - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. CAUTION: If replacing the A/C discharge line, be sure to use the discharge line designed for the A/C compressor in the vehicle. If replacing the 6SEU16 compressor, be sure to use the latest level of A/C discharge line during replacement. Failure to use the correct A/C discharge line could result in possible discharge line and/or compressor damage. NOTE: It is not necessary to completely remove the front fascia for A/C discharge line service. NOTE: 5SE12 A/C compressor shown. 6SEU16 compressor similar. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Remove the splash shield from the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 5. Remove the nut (1) that secures the A/C discharge line (2) to the A/C compressor (3). 6. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened discharge line fitting and the compressor port. 8. Lower the vehicle. 9. Remove the upper radiator closure panel and carefully pull the top of the fascia forward to gain access to the A/C discharge line (3) See: Body and Frame/Spoilers, Flaps, and Air Dams/Air Dam/Service and Repair/Upper Closure Panel - Removal. 10. Reach down through the opening between the radiator and the front fascia and disconnect the wire harness connector (1) from the A/C pressure Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1194 transducer (2). 11. Remove the nut (5) that secures the A/C discharge line to the right side of the A/C condenser (4). 12. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket. 13. Install plugs in, or tape over the discharge line fitting and the condenser port. 14. If necessary, remove the A/C pressure transducer from the A/C discharge line. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1195 Hose/Line HVAC: Service and Repair A/C Discharge Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: If replacing the A/C discharge line, be sure to use the discharge line designed for the A/C compressor in the vehicle. If replacing the 6SEU16 compressor, be sure to use the latest level of A/C discharge line during replacement. Failure to use the correct A/C discharge line could result in possible discharge line and/or compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. 1. If removed, install the A/C pressure transducer (2) onto the A/C discharge line (3). Tighten the A/C pressure transducer securely. 2. Position the A/C discharge line into the engine compartment. 3. Remove the tape or plugs from the discharge line fitting and the condenser port. 4. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Reach down through the opening between the radiator and the front fascia and connect the A/C discharge line to the A/C condenser (4). 6. Install the nut (5) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 5 Nm (44 in. lbs.). 7. Connect the wire harness connector (1) to the A/C pressure transducer. 8. Install the upper radiator closure panel See: Body and Frame/Spoilers, Flaps, and Air Dams/Air Dam/Service and Repair/Upper Closure Panel Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1196 NOTE: 5SE12 A/C compressor shown. 6SEU16 compressor similar. 9. Raise and support the vehicle. 10. Remove the tape or plugs from the discharge line fitting and the compressor port. 11. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 12. Connect the A/C discharge line (2) to the A/C compressor (3). 13. Install the nut (1) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.). 14. Install the splash shield onto the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 15. Lower the vehicle. 16. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 17. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 18. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. 19. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1197 Hose/Line HVAC: Service and Repair A/C Liquid Line - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The A/C liquid line is only serviced as an assembly with the upper A/C suction line. NOTE: LHD model shown in illustrations. RHD model similar. NOTE: Illustration shown with front fascia removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Remove the A/C accumulator See: Heating and Air Conditioning/Accumulator HVAC/Service and Repair/Accumulator - Removal. 5. Reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle and remove the nut (3) that secures the A/C liquid line (1) to the A/C condenser (2). 6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and accumulator ports. 8. Lower the vehicle. 9. Remove the three nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the engine compartment and remove the heat shield. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1198 NOTE: It is only necessary to position the windshield washer reservoir, power steering fluid reservoir and engine coolant reservoir out of the way. Draining of the washer fluid, power steering fluid and engine coolant is not required. 10. Remove the windshield washer reservoir, power steering reservoir and the engine coolant reservoir and position them out of the way. 11. Remove the nut (1) that secures the refrigerant line retaining bracket (2) to the right front strut tower (5). 12. On RHD models, disengage the retainers that secure the power brake booster vacuum supply hose to the dash panel and position the vacuum line out of the way. 13. Remove the bolt (3) that secures the A/C liquid and suction line assembly (4) to the A/C evaporator (6). 14. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals. 15. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports. 16. Remove the A/C liquid and suction line assembly from the engine compartment. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1199 Hose/Line HVAC: Service and Repair A/C Liquid Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: The A/C liquid line must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C liquid line can prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown in illustrations. RHD model similar. 1. Position the A/C liquid and suction line assembly (4) into the engine compartment. 2. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports. 3. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the A/C liquid and suction line assembly to the A/C evaporator (6). 5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 12 Nm (105 in. lbs.). 6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose to the dash panel. 7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5). Tighten the nut to 4.5 Nm (40 in. lbs.). 8. Install the windshield washer reservoir, power steering fluid reservoir and the engine coolant reservoir. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1200 9. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment. 10. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 Nm (10 in. lbs.). NOTE: Illustration shown with front fascia removed for clarity. 11. Raise and support the vehicle. 12. Remove the tape or plugs from the liquid line fitting and the condenser port. 13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 14. Reach up through the opening in the bottom of the front fascia and connect the A/C liquid line (1) to the A/C condenser (2) and install the retaining nut (3). Tighten the nut to 5 Nm (44 in. lbs.). 15. Install the A/C accumulator See: Heating and Air Conditioning/Accumulator HVAC/Service and Repair/Accumulator - Installation. 16. Lower the vehicle. 17. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 18. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 19. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. 20. Charge the A/C system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1201 Hose/Line HVAC: Service and Repair A/C Discharge Line - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. CAUTION: If replacing the A/C discharge line, be sure to use the discharge line designed for the A/C compressor in the vehicle. If replacing the 6SEU16 compressor, be sure to use the latest level of A/C discharge line during replacement. Failure to use the correct A/C discharge line could result in possible discharge line and/or compressor damage. NOTE: It is not necessary to completely remove the front fascia for A/C discharge line service. NOTE: 5SE12 A/C compressor shown. 6SEU16 compressor similar. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Remove the splash shield from the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 5. Remove the nut (1) that secures the A/C discharge line (2) to the A/C compressor (3). 6. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened discharge line fitting and the compressor port. 8. Lower the vehicle. 9. Remove the upper radiator closure panel and carefully pull the top of the fascia forward to gain access to the A/C discharge line (3) See: Body and Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1202 Frame/Spoilers, Flaps, and Air Dams/Air Dam/Service and Repair/Upper Closure Panel - Removal. 10. Reach down through the opening between the radiator and the front fascia and disconnect the wire harness connector (1) from the A/C pressure transducer (2). 11. Remove the nut (5) that secures the A/C discharge line to the right side of the A/C condenser (4). 12. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket. 13. Install plugs in, or tape over the discharge line fitting and the condenser port. 14. If necessary, remove the A/C pressure transducer from the A/C discharge line. A/C Discharge Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: If replacing the A/C discharge line, be sure to use the discharge line designed for the A/C compressor in the vehicle. If replacing the 6SEU16 compressor, be sure to use the latest level of A/C discharge line during replacement. Failure to use the correct A/C discharge line could result in possible discharge line and/or compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. 1. If removed, install the A/C pressure transducer (2) onto the A/C discharge line (3). Tighten the A/C pressure transducer securely. 2. Position the A/C discharge line into the engine compartment. 3. Remove the tape or plugs from the discharge line fitting and the condenser port. 4. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Reach down through the opening between the radiator and the front fascia and connect the A/C discharge line to the A/C condenser (4). 6. Install the nut (5) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 5 Nm (44 in. lbs.). 7. Connect the wire harness connector (1) to the A/C pressure transducer. 8. Install the upper radiator closure panel See: Body and Frame/Spoilers, Flaps, and Air Dams/Air Dam/Service and Repair/Upper Closure Panel Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1203 NOTE: 5SE12 A/C compressor shown. 6SEU16 compressor similar. 9. Raise and support the vehicle. 10. Remove the tape or plugs from the discharge line fitting and the compressor port. 11. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 12. Connect the A/C discharge line (2) to the A/C compressor (3). 13. Install the nut (1) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.). 14. Install the splash shield onto the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 15. Lower the vehicle. 16. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 17. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 18. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. 19. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. A/C Liquid Line - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The A/C liquid line is only serviced as an assembly with the upper A/C suction line. NOTE: LHD model shown in illustrations. RHD model similar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1204 NOTE: Illustration shown with front fascia removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Remove the A/C accumulator See: Heating and Air Conditioning/Accumulator HVAC/Service and Repair/Accumulator - Removal. 5. Reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle and remove the nut (3) that secures the A/C liquid line (1) to the A/C condenser (2). 6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and accumulator ports. 8. Lower the vehicle. 9. Remove the three nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the engine compartment and remove the heat shield. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1205 NOTE: It is only necessary to position the windshield washer reservoir, power steering fluid reservoir and engine coolant reservoir out of the way. Draining of the washer fluid, power steering fluid and engine coolant is not required. 10. Remove the windshield washer reservoir, power steering reservoir and the engine coolant reservoir and position them out of the way. 11. Remove the nut (1) that secures the refrigerant line retaining bracket (2) to the right front strut tower (5). 12. On RHD models, disengage the retainers that secure the power brake booster vacuum supply hose to the dash panel and position the vacuum line out of the way. 13. Remove the bolt (3) that secures the A/C liquid and suction line assembly (4) to the A/C evaporator (6). 14. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals. 15. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports. 16. Remove the A/C liquid and suction line assembly from the engine compartment. A/C Liquid Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: The A/C liquid line must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C liquid line can prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown in illustrations. RHD model similar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1206 1. Position the A/C liquid and suction line assembly (4) into the engine compartment. 2. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports. 3. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the A/C liquid and suction line assembly to the A/C evaporator (6). 5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 12 Nm (105 in. lbs.). 6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose to the dash panel. 7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5). Tighten the nut to 4.5 Nm (40 in. lbs.). 8. Install the windshield washer reservoir, power steering fluid reservoir and the engine coolant reservoir. 9. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment. 10. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 Nm (10 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1207 NOTE: Illustration shown with front fascia removed for clarity. 11. Raise and support the vehicle. 12. Remove the tape or plugs from the liquid line fitting and the condenser port. 13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 14. Reach up through the opening in the bottom of the front fascia and connect the A/C liquid line (1) to the A/C condenser (2) and install the retaining nut (3). Tighten the nut to 5 Nm (44 in. lbs.). 15. Install the A/C accumulator See: Heating and Air Conditioning/Accumulator HVAC/Service and Repair/Accumulator - Installation. 16. Lower the vehicle. 17. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 18. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 19. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. 20. Charge the A/C system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. A/C Suction Line - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The A/C suction line is serviced in two sections. The upper section of the A/C suction line is the refrigerant line that carries refrigerant from the A/C evaporator to the A/C accumulator. The lower section of the A/C suction line carries refrigerant from the A/C accumulator to the A/C compressor. NOTE: LHD model shown in illustrations. RHD model similar. Upper A/C Suction Line NOTE: The upper portion of the A/C suction line is only serviced as an assembly with the A/C liquid line. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1208 NOTE: Illustration shown with front fascia removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Remove the A/C accumulator See: Heating and Air Conditioning/Accumulator HVAC/Service and Repair/Accumulator - Removal. 5. Reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle and remove the nut (3) that secures the A/C liquid line (1) to the A/C condenser (2). 6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and accumulator ports. 8. Lower the vehicle. 9. Remove the three nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the engine compartment and remove the heat shield. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1209 NOTE: It is only necessary to position the windshield washer reservoir, power steering fluid reservoir and engine coolant reservoir out of the way. Draining of the washer fluid, power steering fluid and engine coolant is not required. 10. Remove the windshield washer reservoir, power steering reservoir and the engine coolant reservoir and position them out of the way. 11. Remove the nut (1) that secures the refrigerant line retaining bracket (2) to the right front strut tower (5). 12. On RHD models, disengage the retainers that secure the power brake booster vacuum supply hose to the dash panel and position the vacuum line out of the way. 13. Remove the bolt (3) that secures the A/C liquid and suction line assembly (4) to the A/C evaporator (6). 14. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals. 15. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports. 16. Remove the A/C liquid and suction line assembly from the engine compartment. Lower A/C Suction Line 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant systemSee: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Remove the right front wheel See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Removal. 5. Remove the three push-pin retainers (1) and three screws (2) that secure the front portion of the right front wheelhouse splash shield (3) to body (4) and position the front of the wheelhouse splash shield out of the way to gain access to the A/C accumulator. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1210 6. Remove the nut (2) that secures the lower A/C suction line (3) to the A/C accumulator (1). 7. Disconnect the lower A/C suction line from the A/C accumulator and remove and discard the O-ring seal and gasket. 8. Install plugs in, or tape over the opened suction line fitting and the accumulator port. NOTE: 5SE12 A/C compressor shown. 6SEU16 compressor similar. 9. Remove the nut (1) that secures the lower A/C suction line (2) to the A/C compressor (3). 10. Disconnect the lower A/C suction line from the A/C compressor and remove and discard the O-ring seal and gasket. 11. Install plugs in, or tape over the opened suction line fitting and the compressor port. 12. Remove the lower A/C suction line from the engine compartment. A/C Suction Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown in illustrations. RHD model similar. Upper A/C Suction Line Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1211 1. Position the A/C liquid and suction line assembly (4) into the engine compartment. 2. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports. 3. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the A/C liquid and suction line assembly to the A/C evaporator (6). 5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 12 Nm (105 in. lbs.). 6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose to the dash panel. 7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5). Tighten the nut to 4.5 Nm (40 in. lbs.). 8. Install the windshield washer reservoir, power steering reservoir and the engine coolant reservoir. 9. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment. 10. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 Nm (10 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1212 NOTE: Illustration shown with front fascia removed for clarity. 11. Raise and support the vehicle. 12. Remove the tape or plugs from the liquid line fitting and the condenser port. 13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 14. Reach up through the opening in the bottom of the front fascia and connect the A/C liquid line (1) to the A/C condenser (2) and install the retaining nut (3). Tighten the nut to 5 Nm (44 in. lbs.). 15. Install the A/C accumulator See: Heating and Air Conditioning/Accumulator HVAC/Service and Repair/Accumulator - Installation. 16. Lower the vehicle. 17. Reconnect the negative battery cable. 18. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 19. Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 20. Charge the A/C system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Lower A/C Suction Line NOTE: 5SE12 A/C compressor shown. 6SEU16 compressor similar. 1. Position the lower A/C suction line (2) into the engine compartment. 2. Remove the tape or plugs from the suction line fitting and the compressor port. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the lower A/C suction line to the A/C compressor (3). 5. Install the nut (1) that secures the A/C suction line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 1213 6. Remove the tape or plugs from the suction line fitting and the accumulator port. 7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the lower A/C suction line (3) to the A/C accumulator (1). 9. Install the nut (2) that secures the lower A/C suction line to the A/C accumulator. Tighten the nut to 5 Nm (44 in. lbs.). 10. Reposition the front of the right front wheel house splash shield (3) to the body (4) and install the three push-pin retainers (1) and the three screws (2). Tighten the screws securely. 11. Install the right front wheel See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. 12. Lower the vehicle. 13. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 14. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 15. Adjust the refrigerant oil level See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level. 16. Charge the A/C system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Testing and Inspection Power Steering Line/Hose: Testing and Inspection POWER STEERING PUMP AND HOSES NOTE: This information is designed to be used in conjunction with the diagnostic charts at the beginning of the Steering section. See: Steering and Suspension/Steering/Testing and Inspection CHECKING FOR WEAR OF POWER STEERING PUMP INTERNAL COMPONENTS 1. Place gear selector in PARK (or NEUTRAL) with wheels chalked. 2. With the engine idling, have a helper turn the steering wheel. 3. Using an electronic listening tool, determine if noise is coming from the pump. 4. Increase the engine speed and have a helper turn the steering wheel. Does the noise change with load? 5. Replace the power steering pump if excessive noise is present. See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Power Steering Pump - Removal CHECKING FOR POWER STEERING HOSES TOUCHING BODY OR FRAME OF VEHICLE Check hoses and hose tubes as following: - Inspect hoses and hose tubes for witness marks. If witness marks are present, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque See: Specifications/Mechanical Specifications/Steering/System Specifications. Do not bend tubing to adjust. Replace the hose assembly if damaged. - Check fastener torque of hose mounting brackets and tube nuts. See: Specifications/Mechanical Specifications/Steering/System Specifications - Have a helper bump the steering gear off of the stops to induce pressure fluctuations which may move the hose. If hose contact is made, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque See: Specifications/Mechanical Specifications/Steering/System Specifications. Do not bend tubing to adjust. Replace the hose assembly if damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal Power Steering Line/Hose: Service and Repair Power Steering Hose - Removal Pressure Hose GAS ENGINE NOTE: Before proceeding, See: Steering and Suspension/Steering/Service Precautions . 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the engine appearance cover. 3. Remove the pressure Hose (3) at the pump pressure port (5). 4. Remove the pressure hose routing bracket bolt (2) at the upper mount (8). 5. Remove the pressure hose routing clamp bolt (1) at the exhaust manifold. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 1219 6. Raise and support the vehicle. See: Vehicle Lifting/Service and Repair 7. Remove the return hose (1) at the return tube (2). 8. Remove the return tube (1) at the steering gear (3). 9. Remove the pressure hose (2) at the steering gear (3). 10. Remove the fasteners (1) securing the power steering hose routing clamps (2) to the crossmember. 11. Remove the power steering pressure hose from the vehicle. Return Hose REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 1220 NOTE: Before proceeding, See: Steering and Suspension/Steering/Service Precautions . 1. Remove the engine appearance cover. 2. Remove the coolant recovery bottle. See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Removal 3. Siphon as much fluid as possible from the power steering fluid reservoir. 4. Remove the power steering fluid reservoir.See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Removal 5. Remove the windshield washer reservoir.See: Wiper and Washer Systems/Windshield Washer Reservoir/Service and Repair/Windshield Washer Reservoir - Removal 6. Remove the front fascia. See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Removal 7. Remove the right headlamp. See: Lighting and Horns/Service and Repair/Front Lamp Unit Removal 8. Raise and support the vehicle. See: Vehicle Lifting/Service and Repair 9. Remove the return hose (1) at the return tube (2). 10. Remove the return hose routing clamp screw (2) securing the return hose (7) to the frame rail. 11. Lower the vehicle. 12. Remove the return hose routing clamp screw (1) securing the return hose (7) to the strut tower. 13. Remove the hose clamps (6) securing the return hose to the power steering reservoir and cooler. Slide the hose off the end of the cooler tube. 14. Remove the return hose from the vehicle. Supply Hose GAS ENGINE NOTE: Before proceeding, See: Steering and Suspension/Steering/Service Precautions . Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 1221 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the clamp (2) securing the supply hose to the power steering pump (3) supply fitting, then remove the hose from the supply fitting. 3. Remove the hose clamp securing the supply hose (4) to the power steering fluid reservoir (5). Slide the hose off the end of the reservoir fitting and remove from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 1222 Power Steering Line/Hose: Service and Repair Power Steering Hose - Installation Pressure Hose GAS ENGINE CAUTION: Power steering fluid hoses must remain away from the exhaust system, driveshafts, vehicle components and any unfriendly surface that can possibly damage the hoses. 1. Using a lint free towel, wipe clean the open power steering hose end and the power steering pump port. Replace any used O-rings with new. Lubricate the O-ring with power steering fluid. 2. Install the power steering pressure hose into the engine compartment from below. 3. Install the fasteners (1) securing the power steering hose routing clamps (2) to the crossmember. Use a NEW push clip on the left and tighten the screw on the right to 8 Nm (71 in. lbs.). 4. Install the pressure hose (2) at the gear (3). Tighten the tube nut to 32 Nm (24 ft. lbs.). 5. Install the return tube (1) at the gear (3). Tighten the tube nut to 20 Nm (15 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 1223 6. Install the return hose (1) at the return tube (2). 7. Lower the vehicle. 8. Install the pressure hose (3) at the pump pressure port (5). Tighten the tube nut to 32 Nm (24 ft. lbs.). 9. Install the pressure hose routing bracket bolt (2) to the upper mount (8). 10. Position the pressure hose routing clamp (2) at the exhaust manifold and install the mounting bolt (1). Tighten the bolt to 9 Nm (80 in. lbs.). 11. Fill and bleed the power steering system. See: Steering and Suspension/Steering/Service and Repair/Power Steering System Bleeding 12. Check for leaks. 13. Install the engine appearance cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 1224 Return Hose INSTALLATION 1. Install the power steering return hose (7) into the engine compartment. 2. Install the return hose routing clamp screw (1) securing the return hose (7) to the strut tower. 3. Install the return hose onto the cooler tubes (5) and install the hose clamps (6). 4. Raise and support the vehicle. See: Vehicle Lifting/Service and Repair 5. Install the screw (2) securing the return hose to the frame rail. Tighten the screw to 19 Nm (14 ft. lbs.). 6. Install the return hose (1) at the return tube (2). 7. Lower the vehicle. 8. Install the right headlamp. See: Lighting and Horns/Service and Repair/Front Lamp Unit Installation 9. Install the front fascia. See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Installation 10. Install the windshield washer reservoir. See: Wiper and Washer Systems/Windshield Washer Reservoir/Service and Repair/Windshield Washer Reservoir - Installation 11. Install the power steering fluid reservoir. See: Steering and Suspension/Steering/Power Steering/Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Installation 12. Install the coolant recovery bottle. See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Installation 13. Fill and bleed the power steering system. See: Steering and Suspension/Steering/Service and Repair/Power Steering System Bleeding 14. Check for leaks. 15. Install the engine appearance cover. Supply Hose Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 1225 GAS ENGINE 1. Slide hose clamps (2) onto both ends of the power steering fluid supply hose (1) far enough to clear the fittings on the reservoir and pump once the hose is installed. 2. Place the pump end of the supply hose (1) onto the pump (3) supply fitting. Expand the hose clamp (2) and slide it over the hose and pump supply fitting. Secure the clamp once it is past the bead formed into the fluid supply fitting. 3. Expand the hose clamp (4) at the fluid reservoir (5) and slide it over the hose and fitting. Secure the clamp once it is past the bead formed into the fluid reservoir fitting. 4. Perform the POWER STEERING PUMP BLEED PROCEDURE. See: Steering and Suspension/Steering/Service and Repair/Power Steering System Bleeding 5. Check for leaks at all hose connections. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1231 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1232 Brake Fluid: Specifications Mopar DOT 3, SAE J1703 should be used. If DOT 3, SAE J1703 brake fluid is not available, then DOT 4 is acceptable. Use only recommended brake fluids or equivalent. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1233 Brake Fluid: Description and Operation BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar(R) Brake Fluid or equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1234 Brake Fluid: Testing and Inspection BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid including: the master cylinder and reservoir; proportioning valves (non-ABS); caliper seals; wheel cylinder seals; ABS hydraulic control unit; and all hydraulic fluid hoses. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1235 Brake Fluid: Service and Repair BRAKE FLUID LEVEL CHECKING NOTE: Brake fluid level should be checked a minimum of twice a year. Master cylinder reservoirs (2) are marked, FULL and ADD, indicating the allowable brake fluid level range in the master cylinder fluid reservoir. CAUTION: Use only Mopar(R) Brake Fluid DOT 3 Motor Vehicle or equivalent from a tightly sealed container. Do not use petroleum-based fluid because seal damage in the brake system will result. See: Specifications NOTE: Although there is a range, the preferred level is FULL. 1. Remove the cap (1). 2. Adjust the brake fluid level to the FULL mark listed on the side of the master cylinder fluid reservoir (2) as necessary. Do not overfill the system. 3. Install the cap (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1240 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Page 1241 Clutch Fluid: Specifications Mopar DOT 3, SAE J1703 should be used. No other type of fluid is recommended or approved for use in the clutch hydraulic system. Use only Mopar brake fluid or equivalent from a tightly sealed container. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1246 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Coolant .................................................................................................................................... ............................................... 7.2 Quarts (6.8 Liters) Note: Includes heater and coolant recovery bottled filled to MAX level. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1249 Coolant: Fluid Type Specifications Mopar Antifreeze/Coolant 5 year/100,000 mile formula HOAT (Hybrid Organic Additive Technology) or equivalent. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Description Coolant: Description and Operation Description DESCRIPTION GAS ENGINES WARNING: Antifreeze is an ethylene glycol based coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene glycol. Keep out of reach of children. Dispose of glycol based coolant properly, contact your government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less boiling protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol based coolant with hybrid organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. The green coolant MUST NOT BE MIXED with the orange or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Doing so will reduce the corrosion protection and may result in premature water pump seal failure. If non-HOAT coolant is introduced into the cooling system in an emergency, it should be replaced with the specified coolant as soon as possible. DIESEL ENGINE CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less boiling protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Glysantin G 30-91 Antifreeze/Coolant, 5 Year/150,000 Mile Formula (ASTM D3306), or the equivalent ethylene glycol based coolant. This coolant offers the best engine cooling without corrosion when mixed with 50% coolant and 50% distilled water to obtain a freeze point of -36°C (-34°F). It is dyed purple to distinguish it's unique chemistry from traditional green and yellow silicate coolants. If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. The purple coolant MUST NOT BE MIXED with the orange, green or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant. CAUTION: Glysantin G 30-91 Antifreeze/Coolant, 5 Year/150,00 Mile Formula (ASTM D3306) may not be mixed with any other type of antifreeze. Doing so will reduce the corrosion protection and may result in premature water pump seal failure. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Description > Page 1252 Coolant: Description and Operation Description - HOAT Coolant HOAT COOLANT WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene-glycol. Keep out of reach of children. Dispose of glycol base coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol, but this is not suitable for use in a cooling system. Water also freezes at a higher temperature, boils at a lower temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Description > Page 1253 Coolant: Description and Operation Operation COOLANT Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 1254 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -46°C (-50°F). The use of a hydrometer or a refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer Tool 8286 See: Engine, Cooling and Exhaust/Cooling System/Tools and Equipment will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant corrosion protection will be severely reduced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1259 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1264 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1269 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1274 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1279 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1284 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Specifications > Capacity Specifications Fluid - CVT: Capacity Specifications Automatic Transmission Fluid Capacity Service Fill ........................................................................................................................................... ..................................................... 7.0L ( 14.8 pints ) Overhaul Fill ..................................................... ......................................................................................................................................... 8.1L ( 17.1 pints ) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Specifications > Capacity Specifications > Page 1287 Fluid - CVT: Fluid Type Specifications Automatic Fluid .................................................................................................................................... ....................................................... Mopar CVTF+4 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Specifications > Page 1288 Fluid - CVT: Description and Operation TRANSMISSION FLUIDS NOTE: Refer to the maintenance schedules for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: All transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. TRANSMISSION FLUIDS Mopar (R) CVT+4 is required in the CVT automatic transaxles. Mopar (R) CVT+4 when new is green in color. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. A dark brown/black fluid accompanied with a burnt odor and/or deterioration in shift quality may indicate fluid deterioration or transmission component failure. BG6 and T355 Manual transaxles require the use of Mopar (R) ATF+4 (Automatic Transmission Fluid). FLUID ADDITIVES Chrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various "special" additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of Chrysler and these additives must not be used. The use of transmission "sealers" should also be avoided, since they may adversely affect the integrity of transmission seals. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Testing and Inspection > Causes Of Burnt Fluid Fluid - CVT: Testing and Inspection Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. - Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. - A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. - Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Testing and Inspection > Causes Of Burnt Fluid > Page 1291 Fluid - CVT: Testing and Inspection Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Testing and Inspection > Causes Of Burnt Fluid > Page 1292 Fluid - CVT: Testing and Inspection Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid - failure to clean dipstick and fill tube when checking level - engine coolant entering the fluid - internal failure that generates debris - overheat that generates sludge (fluid breakdown) - failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Service and Repair > Check Oil Level Fluid - CVT: Service and Repair Check Oil Level CHECK OIL LEVEL 1. Verify that the vehicle is parked on a level surface. 2. Remove the dipstick tube cap. WARNING: There is a risk of accident from vehicle starting off by itself when engine is running. There is a risk of injury from contusions and burns if you insert your hands into the engine when it is started or when it is running. Secure vehicle to prevent it from moving off by itself. Wear properly fastened and close-fitting work clothes. Do not touch hot or rotating parts. 3. Actuate the service brake. Start engine and let it run at idle speed in selector lever position "P". 4. Shift through the transmission modes several times with the vehicle stationary and the engine idling. 5. Warm up the transmission, wait at least 2 minutes and check the oil level with the engine running. Push the Oil Dipstick 9336A into transmission fill tube until the dipstick tip contacts the oil pan and pull out again, read off oil level, repeat if necessary. NOTE: The dipstick will protrude from the fill tube when installed. CVT TRANSMISSION FILL GRAPH 6. Check transmission oil temperature using the appropriate scan tool. 7. The transmission Oil Dipstick 9336A has indicator marks every 10 mm. Determine the height of the oil level on the dipstick and using the height, the transmission temperature, and the Transmission Fluid Graph, determine if the transmission oil level is correct. 8. Add or remove oil as necessary and recheck the oil level. 9. Once the oil level is correct, install the dipstick tube cap. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Service and Repair > Check Oil Level > Page 1295 Fluid - CVT: Service and Repair Fluid And Strainer Service FLUID AND STRAINER SERVICE 1. Remove the bolts holding the oil pan (1) to the transaxle case. 2. Remove the oil pan from the transaxle case. 3. Remove the oil pan gasket (1) from the transaxle case. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Service and Repair > Check Oil Level > Page 1296 4. Remove the bolts holding the oil strainer (1) to the valve body. 5. Remove the oil strainer. 6. Remove and discard the oil strainer o-ring. CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring. 7. Install the new o-ring (1) onto the new oil strainer. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Service and Repair > Check Oil Level > Page 1297 8. Install the new oil strainer (1) onto the control valve assembly. Install and tighten the mounting bolts to 8 Nm (70 in. lbs.). CAUTION: Do not re-use the oil pan gasket. Remove any moisture, oil, and used gasket material from the surface where the new gasket is to be installed. When installing the oil pan gasket, align the dowel pin with the dowel pin hole in the oil pan gasket. 9. Install the oil pan gasket (1) onto the transaxle case. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Service and Repair > Check Oil Level > Page 1298 CAUTION: When installing the oil pan, align the dowel pin of the transaxle case with the dowel pin hole of the oil pan. 10. Install the oil pan on the transaxle case (1). Install and tighten the mounting bolts to 8 Nm (70 in.lbs.). NOTE: Only transmission fluid of the type labeled Mopar(R) CVTF+4 (Automatic Transmission Fluid) should be used in this transaxle. 11. Check the oil level See: Check Oil Level Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Service and Repair > Check Oil Level > Page 1299 Fluid - CVT: Service and Repair Transmission Cooler Filter Removal REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the left front tire. 3. Remove the left front splash shield. 4. Drain the coolant. 5. Remove the transmission lines (2) at the cooler (3). 6. Remove the coolant lines (1) at the cooler. 7. Remove the mounting bolts at the cooler. 8. Remove the cooler from the transmission. 9. Remove the fluid filter (1). Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Service and Repair > Check Oil Level > Page 1300 CAUTION: Apply CVT fluid on the seal part when installing the CVT fluid filter. 1. Install the CVT fluid filter (1) into the transaxle case. CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring. 2. Install the new o-ring (1) onto the CVT fluid filter. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Service and Repair > Check Oil Level > Page 1301 3. Install the CVT fluid cooler onto the transaxle case. 4. Install and tighten the mounting bolts to 4 Nm (37 in.lbs.). 5. Install the coolant lines (1) at the cooler. 6. Install the transmission lines (2) at the cooler (3). 7. Install the left front splash shield. 8. Install the left front tire. 9. Lower the hoist. 10. Top off coolant See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 11. Top off transmission fluid . See: Transmission Fill Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Service and Repair > Check Oil Level > Page 1302 Fluid - CVT: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Verify that the vehicle is parked on a level surface. 2. Remove the dipstick tube cap. 3. Add following initial quantity of MOPAR(R) CVTF+4, Automatic Transmission Fluid, to the transmission: a. If only fluid and filter were changed, add 7.0 L (14.8 pts.) of transmission fluid to transmission. b. If the transmission was completely overhauled or the torque converter was replaced or drained, add 8.1 L (17.1 pts.) of transmission fluid to transmission. 4. Check the transmission fluid See: Fluid And Strainer Service and adjust as required. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1307 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications NV T355 .............................................................................................................................................. ......................................... 2.4 - 2.7 L ( 2.5 - 2.8 qts.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1310 Fluid - M/T: Fluid Type Specifications Manual Fluid ........................................................................................................................................ ............................................ Mopar ATF+4 MS9602 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1311 Fluid - M/T: Service and Repair FLUID DRAIN AND FILL NOTE: All T355 Manual Transaxles require the use of ATF+4 (Automatic Transmission Fluid). The transaxle fill plug (1) is located on the left side of the transaxle differential area. The fluid level should be within 3/16 inch from the bottom of the transaxle fill hole (vehicle must be level when checking). The transaxle drain plug (2) is located on the lower right side of the transaxle differential housing. Tighten drain plug to 14 Nm (120 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1316 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Rear Drive Assembly (RDA) ................................................................................................................ ................................................ 500 ml (16.9 ounces) NOTE: Or fill to bottom of fill plug. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1319 Fluid - Differential: Fluid Type Specifications Mopar Gear and Axle lubricant SAE 80W-90 API GL 5 or equivalent non-synthetic product. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1324 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Power Transfer Unit (PTU) .................................................................................................................. ................................................ 540 ml (18.2 ounces) NOTE: Or fill to bottom of fill plug. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1327 Fluid - Transfer Case: Fluid Type Specifications Mopar Gear and Axle lubricant SAE 80W-90 API GL 5 or equivalent non-synthetic product. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1332 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil and Oil Filter ....................................................................................................................... .......................................................... 4.26L (4.5 Qt) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1335 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ............................................................... SAE 5W-20 Use API certified engine oil. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1336 Engine Oil: Description and Operation ENGINE OIL WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your government agency for location of collection center in your area. When service is required, Chrysler Corporation recommends that only Mopar(R) brand parts, lubricants and chemicals be used. Mopar (R) provides the best engineered products for servicing Chrysler Corporation vehicles. Only lubricants bearing designations defined by the following organization should be used: - Society of Automotive Engineers (SAE) - American Petroleum Institute (API) - National Lubricating Grease Institute (NLGI) - Association des Constructeurs Europeens d' Automobiles (European Automobile Manufacturers Association) (ACEA) API CERTIFICATION AND LICENSE SYMBOL Use an engine oil that is API Certified and Licensed to display the certification mark. Mopar (R) provides engine oils that meet or exceed, Material Standard MS-6395 requirement. SAE VISCOSITY Refer to the engine oil filler cap for the preferred engine oil viscosity grade for each vehicle. SAE viscosity grades are used to specify the correct viscosity oil for an engine. Use only Multi-Viscosity oils. These are specified with a dual SAE viscosity grade which indicates the cold (5W) to hot (20) temperature performance range of the oil. CONTAINER IDENTIFICATION The Engine Oil Certification Mark was developed and trademarked by the API to refer customers to those engine oils preferred by the automobile manufacturers. This symbol means that the oil has been certified and licensed by the American Petroleum Institute (API). This certification mark will Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1337 only be found on the front of the oil containers. Those oils that do not display the "Mark" on the front of the container should not be used. Chrysler only recommends API Certified engine oils that meet the requirements of Material Standard MS-6395. Use Mopar or an equivalent oil meeting the specification MS-6395. SYNTHETIC ENGINE OILS There are a number of engine oils being promoted as either synthetic or semi-synthetic. If you choose to use such a product, use only those oils that are certified by the American Petroleum Institute (API) to display the "Certification Mark" and show SAE viscosity grade recommended for each vehicle. Follow the service schedule that describes your driving type. ENGINE OIL ADDITIVES/SUPPLEMENTS The manufacturer does not recommend the addition of any engine oil additives/supplements to the specified engine oil. Engine oil additives/supplements should not be used to enhance engine oil performance. Engine oil additives/supplements should not be used to extend engine oil change intervals. No additive is known to be safe for engine durability and can degrade emission components. Additives can contain undesirable materials that harm the long term durability of engines and emission systems by: - Increasing the level of Phosphorus and Sulfur in the engine oil. The API Certified Engine Oils control the Phosphorus and Sulfur contents of the oil to levels that reduce the contamination effect on the vehicle's emission control system. - Altering the viscosity characteristics of the engine oil so that it no longer meets the requirements of the specified viscosity grade. - Creating potential for an undesirable additive compatibility interaction in the engine crankcase. The engine oils contain a performance additive system carefully developed to optimize the oil's performance in the engine. The addition of supplements may cause the oil to thicken prematurely, cause excessive deposit build-up and potentially shorten engine life. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check Engine Oil: Service and Repair Engine Oil Level Check ENGINE OIL LEVEL CHECK NOTE: The engine must be HOT when checking oil level. The best time to check engine oil level is after the engine is at operating temperature. Allow the engine to be shut off for at least 5 minutes before checking oil level. Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove dipstick (1), and observe oil level. Add oil only when the level is at or below the SAFE mark. If the oil level is in the safe (2) range, do not add oil. CAUTION: Do not operate engine if the oil level is above the MAX mark on the dipstick. Excessive oil volume can cause oil aeration which can lead to engine failure due to loss of oil pressure or increase in oil temperature. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check > Page 1340 Engine Oil: Service and Repair Engine Oil and Filter Change ENGINE OIL AND FILTER CHANGE WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. Change engine oil at mileage and time intervals described in the Maintenance Schedule See: . 1. Run engine until achieving normal operating temperature. 2. Position the vehicle on a level surface and turn engine off. 3. Remove oil fill cap. 4. Raise vehicle on hoist. 5. Place a suitable oil collecting container under oil pan drain plug (2). 6. Remove oil pan drain plug (2) or and allow oil to drain into collecting container. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 7. Remove oil filter (1) See: Filters/Oil Filter/Service and Repair/Removal and Replacement/Engine Oil Filter - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check > Page 1341 8. Install oil pan drain plug (2) and tighten drain plug to 28 Nm (20 ft. lbs.). 9. Install new oil filter (1)See: Filters/Oil Filter/Service and Repair/Removal and Replacement/Engine Oil Filter - Installation. 10. Lower vehicle and fill crankcase with specified type and amount of engine oil and . 11. Install oil fill cap. 12. Start engine and inspect for leaks. 13. Stop engine and inspect oil level. OIL FILTER SPECIFICATION All engines are equipped with a high quality full-flow, disposable type oil filter. Replace oil filter with a Mopar(R) or the equivalent. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING listed above. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1346 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1347 Power Steering Fluid: Specifications Mopar Power Steering Fluid +4 or Mopar ATF+4. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1348 Power Steering Fluid: Description and Operation POWER STEERING FLUID The recommended fluid for the power steering system is Mopar(R) Power Steering fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid. Both Fluids have the same material standard specifications (MS-9602). Mopar(R) ATF+4 (and Mopar(R) Power Steering fluid + 4), when new, is red in color. ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. The power steering system is filled-for-life at the factory and requires no regular maintenance. Although not required at specific intervals, the fluid level may be checked periodically. Check the fluid level anytime there is a system noise or fluid leak suspected. See: Steering and Suspension/Steering/Service and Repair/Power Steering Fluid Level Checking Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1349 Power Steering Fluid: Service and Repair POWER STEERING FLUID LEVEL CHECKING WARNING: Fluid level should be checked with the engine OFF to prevent personal injury from moving parts and to assure an accurate fluid level reading. CAUTION: Mopar(R) Power Steering Fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid is to be used in the power steering system. Both fluids have the same material standard specifications (MS-9602). No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if another fluid is used. Do not overfill the system. NOTE: Although not required at specific intervals, the fluid level may be checked periodically. Check the fluid level anytime there is a system noise or fluid leak suspected. The power steering fluid level can be viewed through the side of the power steering fluid reservoir. Compare the fluid level to the markings on the side of the reservoir. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should read between the MAX. and MIN. markings. When the fluid is hot, fluid level is allowed to read up to the MAX. line. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications REFRIGERANT CHARGE CAPACITY REFRIGERANT CHARGE CAPACITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1354 Refrigerant: Fluid Type Specifications Type...................................................................................................................................................... .........................................................................R-134a Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > A/C Refrigerant Refrigerant: Description and Operation A/C Refrigerant A/C REFRIGERANT The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a nontoxic, nonflammable, clear and colorless liquefied gas. CAUTION: R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure. The A/C refrigerant system is filled-for-life at the factory and requires no regular maintenance. Although not required at specific intervals, the charge level should be checked if system performance deteriorates or if a noise or leak is suspected See: Heating and Air Conditioning/Testing and Inspection. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > A/C Refrigerant > Page 1357 Refrigerant: Description and Operation Refrigerant - Description DESCRIPTION The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming . See: Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > A/C Refrigerant > Page 1358 Refrigerant: Description and Operation Refrigerant - Operation OPERATION R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery Refrigerant: Service and Repair Refrigerant System - Recovery REFRIGERANT SYSTEM RECOVERY WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. When servicing the A/C system, use an R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2788. Per SAE standard J2788, refrigerant recovery stations must recover 95% of the refrigerant system within 30 minutes at 21.1° C (70° F) and be able to measure the amount of refrigerant removed from the system to an accuracy of 28 grams (1 oz.). See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 1361 Refrigerant: Service and Repair Refrigerant System - Evacuate REFRIGERANT SYSTEM EVACUATE CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. NOTE: Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficult to remove and will cause a reliability problem with the A/C compressor. If an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C compressor be used. This will eliminate the possibility of contaminating the refrigerant system. If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system: NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. 1. Recover the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 2. With the engine OFF, connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. Do not operate the engine with a vacuum on the A/C system. 3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge reads to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater) for 30 minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes. 4. Close all valves. Turn off and disconnect the vacuum pump. 5. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 1362 Refrigerant: Service and Repair Refrigerant System - Charge REFRIGERANT SYSTEM CHARGE WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The Underhood HVAC Specification Label contains the refrigerant fill specification of the vehicle being serviced. After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system. Use an R-134a refrigerant recovery/recycling/charging station (1) that meets SAE Standard J2788 to charge the refrigerant system with R-134a refrigerant. See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. CHARGING PROCEDURE CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. See the equipment manufacturer instructions for more information. 1. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 2. A manifold gauge set and an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 should be connected to the refrigerant system. 3. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station See: Heating and Air Conditioning/Specifications/Capacity Specifications. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. 4. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. 5. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 6. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is operating and the blower motor is running at its lowest speed setting. Run the engine at a steady high idle (about 1400 rpm). 7. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system. WARNING: Take care not to open the discharge (high pressure) valve at this time. Failure to follow this warning may result in possible serious or fatal injury. 8. Disconnect the charging station and manifold gauge set from the refrigerant system service ports. 9. Reinstall the caps onto the refrigerant system service ports. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES - 5SE12 A/C COMPRESSOR REFRIGERANT OIL CAPACITIES - 6SEU16 A/C COMPRESSOR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1367 Refrigerant Oil: Fluid Type Specifications The A/C compressor used in this vehicle is designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil in the refrigerant system. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Refrigerant Oil - Description Refrigerant Oil: Description and Operation Refrigerant Oil - Description DESCRIPTION The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils and should never be introduced to an R-134a refrigerant system. There are different PAG oils available and each contain a different additive package. Always use only the type of refrigerant oil recommended for the A/C compressor in the vehicle. CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level can prevent the A/C system from operating as designed and can cause serious A/C compressor damage. The A/C compressor used in this vehicle is designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil in the refrigerant system. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Refrigerant Oil - Description > Page 1370 Refrigerant Oil: Description and Operation Refrigerant Oil - Operation OPERATION After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Page 1371 Refrigerant Oil: Service and Repair REFRIGERANT OIL LEVEL When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The A/C accumulator, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. Drain the refrigerant oil from the A/C compressor using the procedures described below. Failure to properly drain the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. CAUTION: ND-8 PAG refrigerant oil is used in the A/C system. Only refrigerant oil of the same type should be used to service this R-134a A/C system. Do not use any other refrigerant oil. The refrigerant oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from moisture and dirt. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the amount of refrigerant oil being removed during the recovery process. This amount of refrigerant oil should always be added back into the refrigerant system. Refer to the reclaim/recycling equipment manufacturers instructions. It will not be necessary to check the oil level within the A/C refrigerant system or to add oil, unless there has been an oil loss. A refrigerant oil loss may occur due to component replacement or a rupture or leak from a refrigerant line, connector fitting, component or component seal. If a leak does occurs, add 30 milliliters (1 fluid ounce) of the recommended refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when an A/C accumulator, A/C evaporator or A/C condenser is replaced. See Refrigerant Oil Capacities charts. The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor installation. See COMPRESSOR OIL DRAIN PROCEDURES. REFRIGERANT OIL CAPACITIES - 5SE12 A/C COMPRESSOR REFRIGERANT OIL CAPACITIES - 6SEU16 A/C COMPRESSOR COMPRESSOR OIL DRAIN PROCEDURE - DENSO 5SE12 A/C COMPRESSOR CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. The refrigerant oil in the Denso 5SE12 A/C compressor can only be drained using the procedure below. Failure to properly drain the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. NOTE: When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine how much oil should be Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Page 1372 removed from the new A/C compressor (example: new 5SE12 A/C compressor and an accumulator requires 80 ml. (2.7 oz.) of oil to be added to the system. 120 ml. (4.1 oz.) of oil is in new compressor. 120 ml. (4.1 oz.) minus 80 ml. (2.7 oz.) equals 40 ml. (1.4 oz.) oil to be drained from new compressor). If the Denso 5SE12 A/C compressor is being replaced, some refrigerant oil must first be drained from the new A/C compressor. The 5SE12 A/C compressor is filled with 120 milliliters (4.1 oz.) from the factory. Drain 70 milliliters (2.4 oz.) of refrigerant oil from the new 5SE12 compressor. Use the following procedure to drain and measure refrigerant oil from the Denso 5SE12 A/C compressor. 1. Place the new A/C compressor (1) on a workbench. 2. Position the A/C compressor so that the refrigerant oil can drain out of the suction port (2) into a suitable clean measured container. Hold the A/C compressor in this position until no more oil comes out of the compressor port. 3. Reposition the A/C compressor (1) so that the pulley (2) is facing upward and slowly rotate the compressor pulley clockwise one full turn. CAUTION: The 5SE12 A/C compressor is filled with 120 milliliters (4.1 oz.) from the factory. Drain 70 milliliters (2.4 oz.) of refrigerant oil from the new 5SE12 compressor. 4. Repeat steps 2 and 3 at least seven times or until the required amount of refrigerant oil is drained from the new compressor. CAUTION: Failure to properly adjust the refrigerant oil level prior to installation of a replacement compressor can prevent the A/C system from operating as designed and cause serious compressor damage. 5. Install the new A/C compressor onto the engine See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/A/C Compressor Installation. COMPRESSOR OIL DRAIN PROCEDURE - DENSO 6SEU16 A/C COMPRESSOR CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. The refrigerant oil in the Denso 6SEU16 A/C compressor can only be drained using the procedure below. Failure to properly drain the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. If the Denso 6SEU16 A/C compressor is being replaced, some refrigerant oil must first be drained from the new A/C compressor. The 6SEU16 A/C Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Page 1373 compressor is filled with 100 milliliters (3.4 oz.) from the factory. Drain 60 milliliters (2.1 oz.) of refrigerant oil from the new 6SEU16 compressor. Use the following procedure to drain and measure refrigerant oil from the Denso 6SEU16 A/C compressor. 1. Place the new A/C compressor (2) on a workbench and remove the drain plug (1). CAUTION: The 6SEU16 A/C compressor is filled with 100 milliliters (3.4 oz.) from the factory. Drain 60 milliliters (2.1 oz.) of refrigerant oil from the new 6SEU16 compressor when replacing only the compressor. NOTE: When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine how much oil should be removed from the new A/C compressor (example: new 6SEU16 A/C compressor and an accumulator requires 60 ml. (2.1 oz.) of oil to be added to the system. 100 ml. (3.4 oz.) of oil is in new compressor. 100 ml. (3.4 oz.) minus 60 ml. (2.1 oz.) equals 40 ml. (1.4 oz.) oil to be drained from new compressor). 2. Position the A/C compressor so that the refrigerant oil can drain out of the drain port into a suitable clean measured container. Hold the A/C compressor in this position until the required amount of refrigerant oil is drained from the new compressor. CAUTION: Failure to properly adjust the refrigerant oil level prior to installation of a replacement compressor can prevent the A/C system from operating as designed and cause serious compressor damage. 3. Reinstall the drain plug. Tighten the drain plug securely. 4. Install the new A/C compressor onto the engine See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/A/C Compressor Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding Brake Bleeding: Service and Repair Base Brake Bleeding BASE BRAKE BLEEDING NOTE: For bleeding the ABS hydraulic system, refer to Antilock Brake System Bleeding in the Antilock Brake System section. See: Antilock Brake System Bleeding CAUTION: Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder reservoir. CAUTION: Use only Mopar(R) brake fluid or an equivalent from a fresh, tightly sealed container. Brake fluid must conform to DOT 3 specifications. NOTE: For bleeding of the Antilock Brake System, See: . Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process. This will only increase the amount of air in the system and make additional bleeding necessary. Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air into the brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. - Left rear wheel - Right front wheel - Right rear wheel - Left front wheel MANUAL BLEEDING NOTE: To bleed the brakes manually, the aid of a helper will be required. 1. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With the pedal in the down position, open the bleeder screw at least one full turn. 4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 1378 6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir (2) to make sure it does not go dry. 7. Check and adjust brake fluid level to the FULL mark. 8. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. 9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. PRESSURE BLEEDING NOTE: Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. 1. Attach Master Cylinder Cap 6921 (2) in place of the filler cap on the master cylinder reservoir (3). 2. Attach Bleeder Tank C-3496-B (1) or an equivalent, to the Master Cylinder Cap 6921 (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 1379 3. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 4. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 5. After approximately 120-240 ml (4-8 ounces) of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 6. Repeat this procedure at all the remaining bleeder screws. 7. Check and adjust brake fluid level to the FULL mark on the reservoir (2). 8. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. 9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 1380 Brake Bleeding: Service and Repair Antilock Brake System Bleeding ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Brake systems with ABS must be bled as two independent braking systems. The non-ABS portion of the brake system with ABS is to be bled the same as any non-ABS system. The ABS portion of the brake system must be bled separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. NOTE: During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add Mopar(R) DOT 3 brake fluid as required. BLEEDING When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the scan tool to the diagnostics connector. The diagnostic connector is located under the lower steering column cover to the left of the steering column. 3. Using the scan tool, check to make sure the ABM does not have any fault codes stored. If it does, clear them. WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube (1) must be attached to the bleeder screws and submerged in a clear container filled part way with clean brake fluid (2). Direct the flow of brake fluid away from yourself and the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the bleeder screws when opened. NOTE: Pressure bleeding is recommended to bleed the base brake system to ensure all air is removed from system. Manual bleeding may also be used, but additional time is needed to remove all air from system. 4. Bleed the base brake system. See: 5. Using the scan tool, select ECU VIEW, followed by ABS MISCELLANEOUS FUNCTIONS to access bleeding. Follow the instructions displayed. When finished, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 1381 7. Fill the master cylinder fluid reservoir (1) to the FULL level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations Fuse: Locations SPECIFICATIONS An Integrated Power Module (IPM) is located in the engine compartment near the air cleaner assembly. This center contains cartridge fuses and mini-fuses. A label that identifies each component may be printed on the inside of the cover. Refer to "Engine Compartment" of the Owner's Manual for the underhood location of the IPM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 1386 CAUTION: When installing the IPM cover, it is important to ensure the cover is properly positioned and fully latched. Failure to do so may allow water to get into the IPM, and possibly result in an electrical system failure. CAUTION: When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1389 It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1390 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1391 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1392 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1393 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1394 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1395 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1396 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1397 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1398 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1399 Fuse: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1400 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1401 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1402 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Page 1403 Fuse: Application and ID Connector - (IN TIPM) FUSE 10 - (IN TIPM) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Page 1404 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Description and Operation > IOD Fuse - Description Fuse: Description and Operation IOD Fuse - Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the TIPM as part of the preparation procedures performed just prior to new vehicle delivery. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Description and Operation > IOD Fuse - Description > Page 1407 Fuse: Description and Operation IOD Fuse - Operation OPERATION The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Totally Integrated Power Module (TIPM) fuse cavities 7 and 8 in a preset fuse holder. when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Service and Repair > IOD Fuse - Removal Fuse: Service and Repair IOD Fuse - Removal REMOVAL NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the Off position. Failure to place the ignition switch in the Off position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the Off position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the Off position. 2. Remove the cover from the Totally Integrated Power Module (TIPM). 3. Remove fuse 7/8 from the TIPM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Service and Repair > IOD Fuse - Removal > Page 1410 Fuse: Service and Repair IOD Fuse - Installation INSTALLATION CAUTION: It is extremely important that the Ignition Off Draw (IOD) fuses are fully seated into the Totally Integrated Power Module (TIPM) fuse cavities. Failure to install the fuses correctly could result in erratic electrical systems behavior. 1. Remove TIPM cover. 2. Insert fuse 7/8 into the TIPM. Push fuses down until they are fully seated in the TIPM cavities. 3. Install the cover to the TIPM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations Fuse Block: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1414 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1417 It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1418 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1419 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1420 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1421 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1422 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1423 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1424 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1425 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1426 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1427 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1428 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1429 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1430 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1431 Fuse Block: Application and ID Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1432 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Description and Operation > Fuse Block - Description Fuse Block: Description and Operation Fuse Block - Description DESCRIPTION An electrical Fuse Block is located in the left front bumper fascia. It serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. There are two clips that retain the fuse block cover to the fuse block. The cover can be removed to service the fuses and relays by depressing the clips and lifting off the cover. If fuse block wire terminal or insulator service is required the complete fuse block assembly must be removed, See: Service and Repair/Fuse Block - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Description and Operation > Fuse Block - Description > Page 1435 Fuse Block: Description and Operation Fuse Block - Operation OPERATION The fuse block houses relays and blade-type fuses. The fuses, relays and fuse block unit are available for service replacement. Refer to Wiring Diagrams for complete circuit diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Fuse Block - Removal Fuse Block: Service and Repair Fuse Block - Removal REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the front bumper fascia. See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Installation. 3. Depress mounting clips and lift the fuse block off the bracket. 4. Remove the wire harness and fuse block. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Fuse Block - Removal > Page 1438 Fuse Block: Service and Repair Fuse Block - Installation INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Install the new wire harness and fuse block into the vehicle. 2. Position the fuse block onto the mounting bracket and push down until the mounting clips are fully seated. 3. Install the front bumper fascia. See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Removal. 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Relay Box: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1442 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1443 Relay Box: Application and ID Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair To reset the oil change indicator (after performing the scheduled maintenance) refer to the following procedure. 1. Turn the ignition switch to the ON position (Do not start the engine). 2. Fully depress the accelerator pedal slowly three times within 10 seconds. 3. Turn the ignition switch to the OFF/LOCK position. NOTE: If the indicator message illuminates when you start the vehicle, the oil change indicator system did not reset. If necessary, repeat this procedure. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair cr09 HOISTING Refer to Owner's Manual provided with vehicle for proper emergency jacking procedures. WARNING: The hoisting and jack lifting points provided are for a complete vehicle. When the engine or rear suspension is removed from a vehicle, the center of gravity is altered making some hoisting conditions unstable. Properly support or secure vehicle to hoisting device when these conditions exist. CAUTION: Do not position hoisting device on suspension components, damage to vehicle can result.Do not attempt to raise one entire side of the vehicle by placing a floor jack midway between the front and rear wheels. This practice may result in permanent damage to the body. When properly positioned, a floor jack can be used to lift the vehicle and support the raised vehicle with jack stands. A floor jack or any lifting device, must never be used on any part of the underbody other then the described areas. SRT 4 CAUTION: When lifting a Caliber SRT 4 vehicle on a hoist it may be necessary to use 55 mm lift arm spacers to clear the SRT 4 ground effect components. Failure to lift the SRT 4 correctly may result in ground effect component damage. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 1457 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 1458 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Tire Pressure Monitor Receiver / Transponder: Diagrams Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT FRONT (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way > Page 1461 Tire Pressure Monitor Receiver / Transponder: Diagrams Left Rear Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT REAR (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way > Page 1462 Tire Pressure Monitor Receiver / Transponder: Diagrams Right Rear Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-RIGHT REAR (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Description DESCRIPTION A transponder, sometimes referred to as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of a vehicle equipped with Premium TPM. These transponders are used to provide the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. On this vehicle, there is a transponder located in the left front, left rear, and right rear wheelhouse. There is not a transponder located in the right front wheelhouse. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description > Page 1465 Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Operation OPERATION On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (The auto-locating process will start again only if the vehicle has been shut off for approximately 20 minutes or longer). Once the WCM has performed this to the three locations that have transponders, it uses the process-of-elimination theory to figure out the location of the fourth sensor ID. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Removal Front FRONT 1. Remove the wheelhouse splash shield at the transponder requiring service. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 2. Disconnect the wiring harness connector (2) at the transponder (1). 3. Remove the mounting nuts (3), then remove the transponder (1). Rear REAR 1. Remove the wheelhouse splash shield at the transponder requiring service. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 2. Disconnect the wiring harness connector (3) at the transponder (1). 3. Remove the mounting nuts (2), then remove the transponder (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 1468 Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Installation Front FRONT 1. Position the transponder (1) and install the mounting nuts (3). 2. Connect the wiring harness connector (2) to the transponder (1). 3. Install the wheelhouse splash shield and all components removed to access it. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test. Rear REAR 1. Position the transponder (1) and install the mounting nuts (2). 2. Connect the wiring harness connector (3) to the transponder (1). 3. Install the rear wheelhouse splash shield and all components removed to access it. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The Tire Pressure Monitoring (TPM) system has been optimized for the original equipment tires and wheels. TPM system pressures have been established for the tire size equipped on the vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, or style. Aftermarket wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with TPM, as damage to the sensors may result. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: When installing the valve core, be sure to tighten the core to specifications See: Wheels/Specifications . Overtightening by a little as three or four inch pounds can damage the sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a white outline oval (black center) insignia (3) on the sensor body. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1475 The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by either a solid white oval insignia (3) on the body or. . a solid white oval insignia (3) with 433 printed in the center. The sensors are identical except for the oval insignia. The 433 MHz sensors can either have a black or grey sensor body. CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Sensors may be identified by valve stem cap color. From the factory, 315 MHz sensors have a gray valve stem cap while 433 MHz sensors have a black valve stem cap. Otherwise, once mounted inside a tire and wheel assembly you are not able to visually tell the difference between a 315 MHz and 433 MHz sensor. At that point, the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1476 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1477 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer, or from a transponderSee: Relays and Modules - Wheels and Tires/Tire Pressure Monitor Receiver / Transponder/Description and Operation/Tire Pressure Monitoring (TPM) Transponder - Operation. The TPM-RKE Analyzer has the ability to change the sensor's operating mode to PARK MODE and to help diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following operating modes: - SLEEP MODE - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. - PARK MODE - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 psi (6.9 kPa) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 BLOCK MODE - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to PARK MODE using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph (24 km/h). In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 10 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to DRIVE MODE. - DRIVE MODE - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). Anytime the vehicle speed drops below 15 mph (24 km/h), the sensor mode will still be in Drive Mode, but will not transmit until the vehicle reaches speeds over 15 mph (24 km/h) once again. If the vehicle has been stationary for more then 20 minutes, the sensor state will transition to Park Mode. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 mph (24 km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The WCM can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1480 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1481 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1482 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the outer and inner tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. 8. Remove the support and lower the vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1483 b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 1489 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 1490 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Tire Pressure Monitor Receiver / Transponder: Diagrams Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT FRONT (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way > Page 1493 Tire Pressure Monitor Receiver / Transponder: Diagrams Left Rear Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT REAR (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way > Page 1494 Tire Pressure Monitor Receiver / Transponder: Diagrams Right Rear Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-RIGHT REAR (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Description DESCRIPTION A transponder, sometimes referred to as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of a vehicle equipped with Premium TPM. These transponders are used to provide the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. On this vehicle, there is a transponder located in the left front, left rear, and right rear wheelhouse. There is not a transponder located in the right front wheelhouse. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder Description > Page 1497 Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Operation OPERATION On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (The auto-locating process will start again only if the vehicle has been shut off for approximately 20 minutes or longer). Once the WCM has performed this to the three locations that have transponders, it uses the process-of-elimination theory to figure out the location of the fourth sensor ID. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Removal Front FRONT 1. Remove the wheelhouse splash shield at the transponder requiring service. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 2. Disconnect the wiring harness connector (2) at the transponder (1). 3. Remove the mounting nuts (3), then remove the transponder (1). Rear REAR 1. Remove the wheelhouse splash shield at the transponder requiring service. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 2. Disconnect the wiring harness connector (3) at the transponder (1). 3. Remove the mounting nuts (2), then remove the transponder (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 1500 Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Installation Front FRONT 1. Position the transponder (1) and install the mounting nuts (3). 2. Connect the wiring harness connector (2) to the transponder (1). 3. Install the wheelhouse splash shield and all components removed to access it. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test. Rear REAR 1. Position the transponder (1) and install the mounting nuts (2). 2. Connect the wiring harness connector (3) to the transponder (1). 3. Install the rear wheelhouse splash shield and all components removed to access it. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The Tire Pressure Monitoring (TPM) system has been optimized for the original equipment tires and wheels. TPM system pressures have been established for the tire size equipped on the vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, or style. Aftermarket wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with TPM, as damage to the sensors may result. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: When installing the valve core, be sure to tighten the core to specifications See: Wheels/Specifications . Overtightening by a little as three or four inch pounds can damage the sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a white outline oval (black center) insignia (3) on the sensor body. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1506 The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by either a solid white oval insignia (3) on the body or. . a solid white oval insignia (3) with 433 printed in the center. The sensors are identical except for the oval insignia. The 433 MHz sensors can either have a black or grey sensor body. CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Sensors may be identified by valve stem cap color. From the factory, 315 MHz sensors have a gray valve stem cap while 433 MHz sensors have a black valve stem cap. Otherwise, once mounted inside a tire and wheel assembly you are not able to visually tell the difference between a 315 MHz and 433 MHz sensor. At that point, the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1507 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1508 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer, or from a transponderSee: Tire Pressure Monitor Receiver / Transponder/Description and Operation/Tire Pressure Monitoring (TPM) Transponder - Operation. The TPM-RKE Analyzer has the ability to change the sensor's operating mode to PARK MODE and to help diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following operating modes: - SLEEP MODE - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. - PARK MODE - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 psi (6.9 kPa) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 BLOCK MODE - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to PARK MODE using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph (24 km/h). In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 10 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to DRIVE MODE. - DRIVE MODE - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). Anytime the vehicle speed drops below 15 mph (24 km/h), the sensor mode will still be in Drive Mode, but will not transmit until the vehicle reaches speeds over 15 mph (24 km/h) once again. If the vehicle has been stationary for more then 20 minutes, the sensor state will transition to Park Mode. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 mph (24 km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The WCM can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1511 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1512 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1513 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the outer and inner tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. 8. Remove the support and lower the vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1514 b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tires Tires: Description and Operation Tires TIRE Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain, in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: - Rapid acceleration - Severe application of brakes - High-speed driving - Taking turns at excessive speeds - Striking curbs and other obstacles - Operating vehicle with over or under inflated tire pressures Radial ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval shown on Tire Rotation. This will help to achieve a greater tread-life potential. TIRE IDENTIFICATION Tire type, size, load index and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the Tire Identification chart to decipher the code. For example purposes, the tire size P225/60 R 16 97 T is used in the chart. An All Season type tire will also have either M + S, M AND S, or M - S (indicating mud and snow traction) imprinted on the side wall. An Extra or Light Load marking "XL" or "LL" may also be listed on the sidewall. The absence of an "XL" or "LL" marking infers a standard load tire. TIRE IDENTIFICATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 1519 NOTE: * Height (2) ÷ Width (1) = Aspect Ratio. NOTE: ** Consult the tire manufacturer regarding any questions on tire specifications or capabilities. TIRE CHAINS Refer to the owners manual supplied with the vehicle to determine whether the use of tire chains is permitted on this vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 1520 Tires: Description and Operation Spare Tire SPARE TIRE A compact (temporary) spare tire is standard equipment on this vehicle. SRT vehicles and select Export vehicles are equipped with the TIRE FIT tire repair kit as standard equipment in place of a spare tire. It is to be used to repair small punctures in the tire as necessary. A compact spare tire is optional on those select Export Vehicles. The compact spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 80 km/h (50 mph) when using the compact spare tire. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 1521 Tires: Description and Operation Replacement Tires REPLACEMENT TIRES WARNING: Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure. WARNING: In order to maintain the speed capability of the vehicle, replacement tires must have speed ratings equal to or higher than those fitted to the vehicle as original equipment. If tires with lower speed ratings are fitted, the vehicle's handling may be affected and the speed capability of the vehicle may be lowered to the maximum speed capability of the replacement tires. To avoid an accident resulting in severe or fatal injury, consult the tire manufacturer in regards to maximum speed ratings. It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The original equipment tires provide a proper combination of many characteristics such as: - Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability The use of tires smaller than the minimum tire size approved for the vehicle can result in tire overloading and failure. Use tires that have the approved load rating for the vehicle and never overload them. Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure and loss of vehicle control. The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Wear Patterns Tires: Testing and Inspection Tire Wear Patterns TIRE WEAR PATTERNS Under inflation will cause wear on the shoulders of tire. Over inflation will cause wear at the center of tire. Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the other. Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Wear Patterns > Page 1524 Tires: Testing and Inspection Tread Wear Indicators TREAD WEAR INDICATORS Tread wear indicators are molded into the bottom of the tread grooves. When tread depth is 1.6 mm (1/16 in.), the tread wear indicators will appear as a 13 mm (1/2 in.) band (3). Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures Cleaning TIRE CLEANING Before delivery of a vehicle, remove the protective coating on the tires with white sidewalls or raised white letters. To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating away with a soft bristle brush. Steam cleaning may also be used to remove the coating. CAUTION: DO NOT use gasoline, mineral oil, oil-based solvent or a wire brush for cleaning. Tire Inflation Pressures TIRE INFLATION PRESSURES The specified tire pressures have been chosen to provide safe operation, vehicle stability, and a smooth ride. The proper tire pressure specification can be found on the Tire And Loading Information Label provided with the vehicle (usually on the driver's door opening (B-pillar) or rear shut-face of driver's door). A quality air pressure gauge is recommended to check tire air pressure. Tire pressure should be checked cold once per month. Check tire pressure more frequently when the weather temperature varies widely. Tire pressure will decrease when the outdoor temperature drops. After checking the air pressure, replace valve cap finger tight. Inflation pressures specified on the Tire Inflation Pressure Label are always the cold inflation pressure of the tire. Cold inflation pressure is obtained after the vehicle has not been operated for at least 3 hours, or the vehicle is driven less than one mile after being inoperative for 3 hours. Tire inflation pressures may increase from 2 to 6 pounds per square inch (psi) during operation. Do not reduce this normal pressure buildup. Improper inflation can cause: - Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - The vehicle to drift. WARNING: Over or Under inflated tires can affect vehicle handling. The tire can fail suddenly, resulting in loss of vehicle control. Under inflation causes rapid shoulder wear, tire flexing, and can result in tire failure (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1527 Over inflation causes rapid center wear and loss of the tire's ability to cushion shocks (1). Tire Pressure For High Speed Operation TIRE PRESSURE FOR HIGH SPEED OPERATION Refer to the vehicle's Owners Manual Package. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 1528 Tires: Removal and Replacement TIRE LEAK REPAIRING For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area (1). The tire should be replaced if the puncture is located in the sidewall. Deflate tire completely before attempting to dismount the tire from the wheel. Use a lubricant such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and progressively tighten the five wheel nuts to a torque of 135 Nm (100 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information NUMBER: 22-002-09 GROUP: Wheels/Tires DATE: July 29, 2009 SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome Clad wheels to wheel balancing equipment. MODELS: 2004-2008 (CS) Pacifica 2007 - 2009 (D1) Ram Truck (3500 Pick Up) 2007 - 2010 DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2004 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2009-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2008 - 2010 (JS27) Sebring Convertible 2007 - 2010 (JS41) Sebring/Avenger 2007-2010 (KA) Nitro 2002-2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2008 - 2010 (KK) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005-2010 (ND) Dakota 2007 - 2001 (PM) Caliber 2001 - 2009 (PT) Chrysler PT Cruiser 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2008 - 2010 (RI) Town & Country/Grand Caravan Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 1533 2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005-2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander NOTE: This information applies to any model equipped with Chrome Clad Wheels. DISCUSSION: Models equipped with Chrome Clad wheels require specific piloting on balance equipment to properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones. Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1). SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters, contact Pentastar Service Equipment @ 1-800-223-5623. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1534 Wheels: Specifications SPECIFICATIONS BASE WHEEL SRT4 TORQUE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1535 Wheels: Description and Operation DESCRIPTION All vehicles use either steel or cast aluminum drop center wheels. The original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. Every wheel has raised sections between the rim flanges (1) and drop well (3) called safety humps (2). In case of air loss, these raised sections help hold the tire in position on the wheel until the vehicle can be brought to a safe stop. When being installed on the wheel, initial inflation of the tire forces the tire bead over these raised sections into place. The wheel studs and nuts are designed for specific wheel applications and must be replaced with equivalent parts. Do not use replacement parts of lesser quality or of a substitute design. All aluminum and steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1536 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. WARNING: Replacement with used wheels is not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: Chrysler LLC does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For clarification: Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit (93 degrees Celsius). - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure. - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1537 Wheels: Service and Repair WHEEL AND WHEEL TRIM CARE All wheels and wheel trim, especially aluminum and chrome plated, should be cleaned regularly using mild soap and water to maintain their luster and to prevent corrosion. Wash them with the same soap solution recommended for the body of the vehicle. When cleaning extremely dirty wheels, care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to the wheels. Mopar(R) Tire AND Wheel Cleaner, Mopar(R) Wheel Treatment or Mopar(R) Chrome Cleaner is recommended. Any of the "DO NOT USE" items listed below can damage wheels and wheel trim. DO NOT USE: - Any abrasive cleaner - Any abrasive cleaning pad (such as steel wool) or abrasive brush - Any cleaner that contains an acid which can react with and discolor the chrome surface. Many wheel cleaners contain acids that can harm the wheel surface. - Oven cleaner - A car wash that uses carbide-tipped wheel cleaning brushes or acidic solutions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Hub and Bearing - Description Wheel Bearing: Description and Operation Front Hub and Bearing - Description DESCRIPTION The wheel bearing (5) and hub (3) are pressed into the knuckle (1). The wheel bearing is secured in place using a snap ring. One side of the wheel bearing has an integrated magnetic encoder ring for wheel speed sensor usage as equipped. It is important that the wheel speed sensor magnetic encoder ring (dark band) (3) be positioned to the inside of the knuckle or the wheel speed sensor will not operate correctly. The wheel bearing is a Unit 1 type cartridge bearing that requires no maintenance. The wheel bearing can be serviced separately from the hub. The hub supports the driveline halfshaft outer constant velocity (C/V) joint. Each is splined and meshes in the center of the hub. The outer C/V joint is retained to the hub using a nut. The nut is locked to the outer C/V stub shaft using a cotter pin. The hub has five studs pressed into its flange. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Hub and Bearing - Description > Page 1542 Wheel Bearing: Description and Operation Rear Hub and Bearing - Description DESCRIPTION The rear wheel bearing and wheel mounting hub used on this vehicle are a one-piece sealed unit or hub and bearing assembly. It is permanently lubricated when assembled and is sealed for life. There is no periodic lubrication or maintenance recommended for these units. The hub and bearing (5) is mounted to the trailing link (1). All vehicles have a magnetic encoder integrated into the right rear hub and bearing for speed sense. Vehicles equipped with antilock brakes have a magnetic encoder integrated into both rear hub and bearings. The encoder works with the rear wheel speed sensors to provide wheel speed signal. The sensor mounts by screw to the rear of the hub and bearing. The only serviceable components of the hub and bearing are the wheel mounting studs pressed into the hub. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Hub and Bearing Wheel Bearing: Testing and Inspection Front Hub and Bearing WHEEL BEARING AND HUB NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weeping from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Testing and Inspection Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Hub and Bearing > Page 1545 Wheel Bearing: Testing and Inspection Rear Hub and Bearing HUB AND BEARING NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub and bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Testing and Inspection Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal Wheel Bearing: Service and Repair Front Hub and Bearing - Removal REMOVAL NOTE: The removal and installation of the wheel bearing and hub from the knuckle is only to be done with the knuckle removed from the vehicle. 1. Remove the steering knuckle from the vehicle. See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair/Front Steering Knuckle - Removal 2. Position the knuckle support fixture 9712 as follows: a. For left side knuckles, place the locator block (2) to the left side (4) on the Fixture. The side of the locator block with the angle cut goes downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54 Nm (40 ft. lbs.). b. For right side knuckles, place the locator block (2) to the right side (3) on the Fixture. The side of the locator block with the angle cut goes downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54 Nm (40 ft. lbs.). 3. Install the knuckle in the Fixture as shown, guiding the steering arm (1) to rest on the locator block (3) and the brake caliper mounting bosses on the two Fixture pins (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1548 4. Place the Fixture (3) with knuckle in an arbor press. 5. Position Remover/Installer 9712-2 (2), in the small end of the hub. Lower the arbor press ram (1) and remove the hub from the wheel bearing and knuckle. The bearing race will normally come out of the wheel bearing with the hub as it is pressed out of the bearing. 6. Remove the knuckle from the Fixture and turn it over. 7. Remove the snap ring (2) from the knuckle using an appropriate pair of snap ring pliers (1). 8. Place the knuckle back in the Fixture (3) in the arbor press ram. 9. Place Installer (2) MD-998334, on the outer race of the wheel bearing. Lower the arbor press ram (1) and remove the wheel bearing from the knuckle. 10. Remove the knuckle and tools from arbor press. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1549 11. If the bearing race is still pressed onto the hub, install the Bearing Splitter (5), Special Tool 1130, between the hub flange and the bearing inner race (4). 12. Place the hub, bearing race and Bearing Splitter in an arbor press. The press support blocks must not obstruct the wheel hub while it is being pressed out of the bearing race. 13. Place Remover/Installer 9712-2 (2) in the end of the hub (3). Lower the arbor press ram (1) and remove the hub from the bearing race. NOTE: For installation, See: Front Hub and Bearing - Installation . Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1550 Wheel Bearing: Service and Repair Front Hub and Bearing - Installation INSTALLATION CAUTION: When installing the wheel bearing (1) in the knuckle (2) it is important to place the side of bearing with the wheel speed sensor magnetic encoder ring (dark band) (3) in the knuckle first. Otherwise, the wheel speed sensor will not operate correctly. 1. Wipe the bearing bore of the knuckle clean of any grease or dirt with a clean, dry shop towel. 2. Place the knuckle in an arbor press supporting the knuckle from underneath using Cup 6310-1 (4.) 3. Place the NEW wheel bearing (5) magnetic encoder ring side down (see above Caution) into the bore of the knuckle. Be sure the wheel bearing is placed squarely into the bore. 4. Place Receiver 8498 (3), larger inside diameter end down over the outer race of the wheel bearing. 5. Place Disc 6310-2 (2) into top of Receiver 8498. Lower the arbor press ram (1) and press the wheel bearing into the knuckle until it is bottomed in the bore of the knuckle. 6. Remove the knuckle and tools from the arbor press. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1551 7. Install a NEW snap ring (2) in the knuckle using an appropriate pair of snap ring pliers (1). Make sure the snap ring is fully seated. 8. Place the knuckle in an arbor press. Support the knuckle from underneath using Remover/Installer MB-990799 (3), smaller end up against the wheel bearing inner race. 9. Place the hub (4) in the wheel bearing making sure it is square with the bearing inner race. 10. Position Remover/Installer 9712-2 (2) in the end of the hub. Lower the arbor press ram (1) and press the hub into the wheel bearing until it bottoms. 11. Remove the knuckle and tools from the press. 12. Verify the hub turns smoothly without rubbing or binding. 13. Install the knuckle on the vehicle. See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair/Front Steering Knuckle Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1552 Wheel Bearing: Service and Repair Rear Hub and Bearing - Removal REMOVAL NOTE: Before proceeding, See: Steering and Suspension/Suspension/Service Precautions/Vehicle Damage Warnings . 1. Raise and support the vehicle. See: Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. 3. Remove the disc brake caliper (2) lower guide pin bolt (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1553 CAUTION: When moving rear brake caliper upward, use extreme care not to damage or overextend the flex hose. Damage may occur. 4. Rotate the caliper upward hinging off the upper guide pin bolt. Rotate the caliper upward just enough to allow brake rotor removal. Hang the caliper assembly in this position using wire or a bungee cord. 5. Remove any clips (2) retaining the brake rotor (3) to the wheel mounting studs. 6. Slide the brake rotor (3) off the hub and bearing (1). 7. Remove the screw (1) fastening the wheel speed sensor head (3) in the rear of the hub and bearing (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1554 8. Remove the four bolts (1) securing the hub and bearing (2) to the trailing link. 9. Remove the hub and bearing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1555 Wheel Bearing: Service and Repair Rear Hub and Bearing - Installation FRONT-WHEEL-DRIVE NOTE: If equipped, make sure the wheel speed sensor mount on the rear of the hub and bearing is directed toward the front of the vehicle. 1. Position the hub and bearing on the brake support plate and trailing link. 2. Install the four bolts (1) securing the hub and bearing (2) to the trailing link. Tighten the bolts to 105 Nm (77 ft. lbs.). NOTE: Before installing the wheel speed sensor head (3) into the rear of the hub and bearing (2), inspect the O-ring seal to make sure it is not dislodged, split, cut or damaged in any way. Replace the O-ring as necessary. 3. If equipped with a wheel speed sensor, install the wheel speed sensor head (3) into the rear of the hub and bearing (2). 4. If equipped with a wheel speed sensor, install the wheel speed sensor head mounting screw (1). Tighten the screw to 10 Nm (89 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 1556 5. Slide the brake rotor (3) over the parking brake shoes and onto the hub and bearing (1). 6. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 7. Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 60 Nm (44 ft. lbs.). 8. Install tire and wheel assembly (1) See: Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. 10. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving it. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Wheel Cover - Removal Wheel Cover: Service and Repair Wheel Cover - Removal REMOVAL 1. Raise and support the vehicle so that tire and wheel assembly clears ground level. See: Vehicle Lifting/Service and Repair CAUTION: When removing the bolt-on wheel cover, do not attempt to pry the wheel cover off the wheel. It is held on by the wheel mounting nuts. 2. Remove the five wheel mounting (lug) nuts (3) from the wheel studs. While removing the nuts, hold the wheel cover (2) in place so it doesn't fall off when the last nut is removed. 3. Remove the wheel cover (2) using care not to let the tire and wheel assembly (1) fall off the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Wheel Cover - Removal > Page 1561 Wheel Cover: Service and Repair Wheel Cover - Installation INSTALLATION WARNING: Installing wheels without good metal-to-metal contact with the mounting surface could cause loosening of the wheel mounting (lug) nuts. This could adversely affect the safety and handling of the vehicle. NOTE: Never use oil or grease on studs or wheel mounting (lug) nuts. 1. With the tire and wheel assembly (1) positioned on the wheel studs without the wheel mounting (lug) nuts installed, align the valve notch in the wheel cover with the valve stem on the wheel and install the wheel cover over the studs. NOTE: Always use the original (OEM) style wheel mounting (lug) nuts. Do not use replacement parts of lesser quality or substitute design. 2. Install and lightly snug all five wheel mounting (lug) nuts (3) Do not tighten at this time. 3. Lower the vehicle. 4. Progressively tighten all wheel mounting (lug) nuts in the proper sequence shown. Tighten the nuts to a final torque of 135 Nm (100 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front Suspension Axle Nut: Specifications Front Suspension AXLE NUT Hub Nut................................................................................................................................................ ....................................................244 Nm (180 ft.lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front Suspension > Page 1567 Axle Nut: Specifications Rear Suspension AXLE NUT Hub Nut................................................................................................................................................ ....................................................245 Nm (181 ft.lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Mounting (Lug) Nut.................................................................................................................... ..................................................135 Nm (100 ft.lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal Wheel Fastener: Service and Repair Wheel Stud - Removal Front REMOVAL NOTE: Use the following procedure to remove one of five studs on one wheel hub. 1. Access and remove front brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal CAUTION: Do not hammer wheel mounting studs out of the hub. Damage to the wheel bearing will occur, leading to premature bearing failure. 2. Install Remover 8677 (3) on the hub flange (1) and wheel stud (2). 3. Tighten the Remover, pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of the stud is past the flange, remove the Remover from the hub. 4. Remove the stud from the hub flange. Rear REMOVAL NOTE: Use the following procedure to remove one of five studs on one wheel hub. 1. If equipped with rear disc brakes, access and remove brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. If equipped with rear drum brakes, access and remove brake drum. See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement/Removal CAUTION: Do not hammer wheel mounting studs out of the hub. Damage to the wheel bearing will occur, leading to premature bearing failure. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 1573 3. Install Remover 8677 (1) on the hub flange (2) and wheel stud (3). 4. Rotate the hub around until an open spot is found directly behind the wheel stud. 5. Tighten the Remover, pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of the stud is past the flange, remove the Remover from the hub. 6. Remove the stud from the hub flange. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 1574 Wheel Fastener: Service and Repair Wheel Stud - Installation Front INSTALLATION NOTE: Use the following procedure to install one of five studs on one wheel hub. 1. Install the NEW wheel mounting stud in the flange of the hub (2) from the rear. 2. Install several washers (1) and a standard wheel mounting (lug) nut (3) on the stud (4). Install the mounting nut so that the flat side of the nut is against the washers to eliminate any binding. 3. Tighten the wheel mounting nut. This will pull the wheel mounting stud into the hub flange. When the head of the stud is fully seated against the rear of the hub flange, remove the wheel mounting nut and washers. 4. Install the brake rotor and all components previously removed to access it. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation Rear INSTALLATION NOTE: Use the following procedure to install one of five studs on one wheel hub. 1. Install the NEW wheel mounting stud in the flange of the hub (2) from the rear. 2. Install several washers (1) and a standard wheel mounting (lug) nut (3) on the stud (4). Install the mounting nut so that the flat side of the nut is against the washers to eliminate any binding. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 1575 3. Tighten the wheel mounting nut. This will pull the wheel mounting stud into the hub flange. When the head of the stud is fully seated against the rear of the hub flange, remove the wheel mounting nut and washers. 4. If equipped with rear disc brakes, install the brake rotor and all components previously removed to access it. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation 5. If equipped with rear drum brakes, install the brake drum and tire and wheel assembly. See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement/Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service and Repair Jump Starting: Service and Repair JUMP STARTING WARNING: Review all safety precautions and warnings in battery/starting/charging sections. Do not jump start a frozen battery, personal injury can result. Do not jump start when maintenance free battery indicator dot is yellow or bright color. Do not jump start a vehicle when the battery fluid is below the top of lead plates. Do not allow jumper cable clamps to touch each other when connected to a booster source. Do not use open flame near battery. Remove metallic jewelry worn on hands or wrists to avoid injury by accidental arcing of battery current. When using a high output boosting device, do not allow battery voltage to exceed 16 volts. Refer to instructions provided with device being used. CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle. TO JUMP START A DISABLED VEHICLE: 1. Raise hood on disabled vehicle and visually inspect engine compartment for: - Battery cable clamp condition, clean if necessary. - Frozen battery. - Yellow or white color test indicator, if equipped. - Generator drive belt condition and tension. - Fuel fumes or leakage, correct if necessary. CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result. 2. When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn off all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF. 3. On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all accessories. 4. Connect jumper cables to booster battery. RED clamp to positive terminal (+) or remote terminal. BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure. 5. On disabled vehicle connect RED jumper cable clamp to positive (+) remote terminal. Connect BLACK jumper cable clamp to engine ground. a. Pull the protective sleeve from the remote positive terminal labeled Position Jump Post Attachment. b. Connect RED jumper cable clamp to positive (+) remote terminal. c. Connect BLACK jumper cable clamp to Negative Jump Post Attachment or engine ground as close to the ground cable attaching point as possible 6. Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery. CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail. 7. Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 minutes), before cranking again. DISCONNECT CABLE CLAMPS AS FOLLOWS: - Disconnect BLACK cable clamp from engine ground on disabled vehicle. - Disconnect RED cable clamp from battery positive remote terminal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Trailer Towing Towing Information: Service and Repair Trailer Towing SPECIFICATIONS - TOWING, Trailer - NAFTA In this article, you will find safety tips and information on limits to the type of towing you can reasonably do with your vehicle. Before towing a trailer carefully review this information to tow your load as efficiently and safely as possible. To maintain warranty coverage, follow the requirements and recommendations concerning vehicles used for trailer towing. Common Towing Definitions The following trailer towing related definitions assists you in understanding the following information: Gross Vehicle Weight Rating (GVWR) The GVWR is the total allowable weight of your vehicle. This includes driver, passengers, cargo and tongue weight. The total load must be limited so that you do not exceed the GVWR. Gross Trailer Weight (GTW) The Gross Trailer Weight (GTW) is the weight of the trailer plus the weight of all cargo, consumables and equipment (permanent or temporary) loaded in or on the trailer in its "loaded and ready for operation" condition. The recommended way to measure GTW is to put your fully loaded trailer on a vehicle scale. The entire weight of the trailer must be supported by the scale. Gross Combination Weight Rating (GCWR) The Gross Combination Weight Rating (GCWR) is the total permissible weight of your vehicle and trailer when weighed in combination. (Note that GCWR ratings include a 68 kg (150 lbs) allowance for the presence of a driver). Gross Axle Weight Rating (GAWR) The GAWR is the maximum capacity of the front and rear axles. Distribute the load over the front and rear axles evenly. Make sure that you do not exceed either the front or rear GAWR. WARNING: It is important that you do not exceed the maximum front or rear GAWR. A dangerous driving condition can result if either rating is exceeded. Failure to follow these instructions may result in serious or fatal injury. Tongue Weight (TW) The tongue weight is the downward force exerted on the hitch ball by the trailer. In most cases it should not be less than 10% or more than 15% of the trailer load. You must consider this as part of the load on your vehicle. Frontal Area The frontal area is the maximum height and maximum width of the front of a trailer. Trailer Sway Control The trailer sway control is a telescoping link that can be installed between the hitch receiver and the trailer tongue that typically provides adjustable friction associated with the telescoping motion to dampen any unwanted trailer swaying motions while traveling. Weight-Carrying Hitch A weight-carrying hitch supports the trailer tongue weight, just as if it were luggage located at a hitch ball or some other connecting point of the truck. These kind of hitches are the most popular on the market today and they're commonly used to tow small- and medium-sized trailers. Weight-Distributing Hitch Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Trailer Towing > Page 1583 Weight Distributing Hitch System A weight-distributing system works by applying leverage through spring (load) bars. They are typically used for heavier loads, to distribute trailer tongue weight to the tow vehicle's front axle and the trailer axle(s). When used in accordance with the manufacturers' directions, it provides for a more level ride, offering more consistent steering and brake control thereby enhancing towing safety. The addition of a friction / hydraulic sway control also dampens sway caused by traffic and crosswinds and contributes positively to tow vehicle and trailer stability. Trailer sway control and a weight distributing (load equalizing) hitch are recommended for heavier Tongue Weights (TW) and may be required depending on Vehicle and Trailer configuration / loading to comply with gross axle weight rating (GAWR) requirements. Improper Adjustment of Weight Distributing System WARNING: An improperly adjusted Weight Distributing Hitch system may reduce handling, stability, braking performance, and could result in an accident. Weight Distributing Systems may not be compatible with Surge Brake Couplers. Consult with your hitch and trailer manufacturer or a reputable Recreational Vehicle dealer for additional information. Failure to follow these instructions may result in possible serious or fatal injury. Installing A Trailer Hitch NOTE: If you install a trailer hitch after you purchase the vehicle, you must install a Mopar (R) spare tire hold down kit. The kit allows you to properly secure the spare tire and jack assembly. WARNING: Do not operate the vehicle without a properly secured tire and jack assembly. Any loose items may be thrown forward in a collision or hard stop and strike occupants. Failure to follow these instructions may result in possible serious or fatal injury. Trailer Hitch Classification The following chart provides the industry standard for the maximum trailer weight a given trailer hitch class can tow and should be used to assist you in selecting the correct trailer hitch for your intended towing condition. Refer to the Trailer Towing Weights (Maximum Trailer Weight Ratings) chart for the Maximum GTW towable for your given drivetrain. All trailer hitches should be professionally installed on your vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Trailer Towing > Page 1584 Trailer Towing Weights (Maximum Trailer Weight Ratings) The following chart provides the maximum trailer weight ratings towable for your given drivetrain. NOTE: The trailer tongue weight must be considered as part of the combined weight of occupants and cargo and should never exceed the weight referenced on the Tire and Loading Information placard. Trailer and Tongue Weight Always load a trailer with 60% to 65% of the weight in the front of the trailer. This places 10% to 15% of the Gross Trailer Weight (GTW) on the tow hitch of your vehicle. Loads balanced over the wheels or heavier in the rear can cause the trailer to sway severely side to side which will cause loss of control of the vehicle and trailer. Failure to load trailers heavier in front is the cause of many trailer accidents. Never exceed the maximum tongue weight stamped on your bumper or trailer hitch. Consider the following items when computing the weight on the rear axle of the vehicle: - The tongue weight of the trailer. - The weight of any other type of cargo or equipment put in or on your vehicle. - The weight of the driver and all passengers. NOTE: Remember that everything put into or on the trailer adds to the load on your vehicle. Also, additional factory-installed options, or dealer-installed options, must be considered as part of the total load on your vehicle. Refer to the Tire and Loading Information placard in the Tire Safety Information Section for the maximum combined weight of occupants and cargo for your vehicle. Towing Requirements To promote proper break-in of your new vehicle drivetrain components, the following guidelines are recommended: CAUTION: - Avoid towing a trailer for the first 500 mi (805 km) of vehicle operation. Doing so may damage the vehicle. - During the first 500 mi (805 km) of trailer towing, limit the speed to 50 mph (80 km/h). When towing a trailer, never exceed the GAWR or GCWR, ratings. WARNING: Improper towing can lead to an injury accident. Follow these guidelines to make the trailer towing as safe as possible: Make certain that the load is secured in the trailer and will not shift during travel. When trailering cargo that is not fully secured, dynamic load shifts can occur that may be difficult for the driver to control. Failure to follow these instructions may result in serious or fatal injury. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Trailer Towing > Page 1585 - When hauling cargo or towing a trailer, do not overload your vehicle or trailer. Overloading can cause a loss of control, poor performance or damage to the brakes, axle, engine, transmission, steering, suspension, chassis structure or tires. - Safety chains must always be used between your vehicle and trailer. Always connect the chains to the frame or hook retainers of the vehicle hitch. Cross the chains under the trailer tongue and allow enough slack for turning corners. - Vehicles with trailers should not be parked on a grade. When parking, apply the parking brake on the tow vehicle. Put the tow vehicle automatic transmission in PARK. With a manual transmission, shift the transmission into REVERSE. Always block or "chock" the trailer wheels. - GCWR must not be exceeded. - Total weight must be distributed between the tow vehicle and the trailer such that the following four ratings are not exceeded: - GVWR - GTW - GAWR - Tongue weight rating for the trailer hitch utilized (this requirement may limit the ability to always achieve the 10% to 15% range of tongue weight as a percentage of total trailer weight). Towing Requirements - Tires - Do not attempt to tow a trailer while using a compact spare tire. - Proper tire inflation pressures are essential to the safe and satisfactory operation of your vehicle. Refer to the "Tires-General Information" section under Tire Pressures for proper tire inflation procedures. - Also, check the trailer tires for proper tire inflation pressures before trailer usage. - Check for signs of tire wear or visible tire damage before towing a trailer. Refer to "Tread Wear Indicators" under "Tires-General Information" in Section 5 under for the proper inspection procedure. - When replacing tires, See: Wheels and Tires/Tires/Description and Operation for information on replacement tires and for the proper tire replacement procedures. Replacing tires with a higher load carrying capacity will not increase the vehicle's GVWR and GAWR limits. Towing Requirements - Trailer Brakes - Do not interconnect the hydraulic brake system or vacuum system of your vehicle with that of the trailer. This could cause inadequate braking and possible personal injury. - An electronically actuated trailer brake controller is required when towing a trailer with electronically actuated brakes. When towing a trailer equipped with a hydraulic surge actuated brake system, an electronic brake controller is not required. - Trailer brakes are recommended for trailers over 1,000 lbs (450 kg) and required for trailers in excess of 2,000 lbs (907 kg). CAUTION: If the trailer weighs more than 1,000 lbs (450 kg) loaded, it should have its own brakes and they should be of adequate capacity. Failure to do this could lead to accelerated brake lining wear, higher brake pedal effort, and longer stopping distances. WARNING: Do not connect trailer brakes to your vehicle's hydraulic brake lines. It can overload your brake system and cause it to fail. You might not have brakes when you need them and could have an accident. Towing any trailer will increase your stopping distance. When towing, you should allow for additional space between your vehicle and the vehicle in front of you. Failure to follow these instructions may result in possible serious or fatal injury. Towing Requirements - Trailer Lights AND Wiring 4 - Pin Connector Whenever you pull a trailer, regardless of the trailer size, stoplights and turn signals on the trailer are required for motoring safety. The Trailer Tow Package may include a 4- and 7-pin wiring harness. Use a factory approved trailer harness and connector. NOTE: Do not cut or splice wiring into the vehicles wiring harness. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Trailer Towing > Page 1586 The electrical connections are all complete to the vehicle but you must mate the harness to a trailer connector. Refer to the following illustrations. 7- Pin Connector Towing Tips Before setting out on a trip, practice turning, stopping and backing the trailer in an area away from heavy traffic. If using a manual transmission vehicle for trailer towing, all starts must be in 1st gear to avoid excessive clutch slippage. Electronic Speed Control (If Equipped) - Do not use in hilly terrain or with heavy loads. - When using the speed control, if you experience speed drops greater than 10 mph (16 km/h), disengage it until you can get back to cruising speed. - Use speed control in flat terrain and with light loads to maximize fuel efficiency. Cooling System To reduce potential for engine and transmission overheating, take the following actions: - City Driving - When stopped for short periods of time, put transmission in neutral and increase engine idle speed. - Highway Driving - Reduce speed. - Air Conditioning - Turn off temporarily. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Trailer Towing > Page 1587 Towing Information: Service and Repair Vehicle Towing VEHICLE TOWING WARNING: Do not allow towing attachment devices to contact the fuel tank or lines, fuel leak can result. Do not lift or tow vehicle by front or rear bumper, or bumper energy absorber units. Do not venture under a lifted vehicle if not supported properly on safety stands. Do not allow passengers to ride in a towed vehicle. Use a safety chain that is independent from the towing attachment device. Failure to follow these instructions may result in possible serious or fatal injury. CAUTION: Do not damage brake lines, exhaust system, shock absorbers, sway bars, or any other under vehicle components when attaching towing device to vehicle. Do not attach towing device to front or rear suspension components. Do not secure vehicle to towing device by the use of front or rear suspension or steering components. Remove or secure loose or protruding objects from a damaged vehicle before towing. Refer to state and local rules and regulations before towing a vehicle. Do not allow weight of towed vehicle to bear on lower fascia, air dams, or spoilers. To avoid damage to bumper fascia and air dams use of a wheel lift or flat bed towing device is recommended. When using a wheel lift towing device, be sure the un-lifted end of disabled vehicle has at least 100 mm (4 in.) ground clearance. If minimum ground clearance cannot be reached, use a towing dolly. If a flat bed device is used, the approach angle should not exceed 15 degrees. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Trailer Towing > Page 1588 Towing Information: Service and Repair Recreational Towing (Behind Motorhome, etc.) STANDARD PROCEDURE - RECREATIONAL TOWING (BEHIND MOTORHOME, ETC.) Towing This Vehicle Behind Another Vehicle (Flat Towing With All Four Wheels On The Ground) NOTE: Vehicles equipped with manual transaxles may be recreationally towed (flat towed) at any legal highway speed, for any distance, if the manual transaxle is in NEUTRAL and the ignition key is in the ACC position. CAUTION: - DO NOT FLAT TOW any vehicle equipped with an AUTOMATIC TRANSAXLE. Damage to the drivetrain will result. If these vehicles require towing, make sure all four wheels are off the ground. - Front or rear wheel lifts should not be used. Internal damage to the transaxle will occur if a front or rear wheel lift is used when recreational towing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair cr09 HOISTING Refer to Owner's Manual provided with vehicle for proper emergency jacking procedures. WARNING: The hoisting and jack lifting points provided are for a complete vehicle. When the engine or rear suspension is removed from a vehicle, the center of gravity is altered making some hoisting conditions unstable. Properly support or secure vehicle to hoisting device when these conditions exist. CAUTION: Do not position hoisting device on suspension components, damage to vehicle can result.Do not attempt to raise one entire side of the vehicle by placing a floor jack midway between the front and rear wheels. This practice may result in permanent damage to the body. When properly positioned, a floor jack can be used to lift the vehicle and support the raised vehicle with jack stands. A floor jack or any lifting device, must never be used on any part of the underbody other then the described areas. SRT 4 CAUTION: When lifting a Caliber SRT 4 vehicle on a hoist it may be necessary to use 55 mm lift arm spacers to clear the SRT 4 ground effect components. Failure to lift the SRT 4 correctly may result in ground effect component damage. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > Camshaft Position Solenoid 1/1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > Camshaft Position Solenoid 1/1 > Page 1599 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Diagrams > Camshaft Position Solenoid 1/1 (Powertrain) 2 Way Variable Valve Timing Solenoid: Diagrams Camshaft Position Solenoid 1/1 (Powertrain) 2 Way Connector - (POWERTRAIN) 2 WAY SOLENOID-CAMSHAFT 1/1 POSITION - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Diagrams > Camshaft Position Solenoid 1/1 (Powertrain) 2 Way > Page 1602 Variable Valve Timing Solenoid: Diagrams Camshaft Position Solenoid 1/2 (Powertrain) 2 Way Connector - (POWERTRAIN) 2 WAY SOLENOID-CAMSHAFT 1/2 POSITION - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Valve Timing Solenoid - Description Variable Valve Timing Solenoid: Description and Operation Variable Valve Timing Solenoid Description DESCRIPTION Variable valve timing solenoid assembly. The solenoid receives pulse width modulation signal and the current is controlled within 0 ma to 1000 ma. The spool position is controllable at any position to control supply of oil between the advance and retard ports. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Valve Timing Solenoid - Description > Page 1605 Variable Valve Timing Solenoid: Description and Operation Variable Valve Timing Solenoid Operation OPERATION There is both an Intake and an exhaust camshaft sensor on vehicles equipped with a World Engine. The variable valve timing system used on World Engines requires the exact position of both the intake and exhaust camshaft. The GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of the camshafts. Intake and exhaust phaser oil control valves are required on World Engine vehicles using variable valve timing. The oil valves direct oil to the Intake and exhaust phasers. Oil pressure in the phasers moves the camshafts to an advanced or retarded position. To resolve this inherent conflict between optimum high and low speed valve timing, the GPEC1 controlled engine uses a variable valve timing system. The variable valve timing system advances and retards valve timing by rotating the position of both the intake and exhaust camshafts. With this system, the intake valve opening can range from 80 to 120 crankshaft degrees after Top Dead Center. Likewise, the exhaust valve opening can range from 85 to 120 crankshaft degrees before Top Dead Center. This degree of flexibility provides many benefits, including: Improved Engine Performance, Increased Fuel Economy, Improved Idle Stability and Decreased Engine Emissions. In non operating condition, the camshaft stays in lockpin position of cam phases. This is 120 degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust camshaft. The variable valve timing system is electronically controlled and hydraulically operated. The GPEC1 receives information from many sensors to determine the optimum valve timing. It then pulse-width modulates oil control valves which direct oil to the cam phasers. The cam phasers use oil pressure to rotate the intake and exhaust camshafts. The rotation of the camshafts is referred to as cam phasing. Before the GPEC1 can begin commanding the camshaft phasing, several enabling conditions must be met: - The engine oil temperature must be at least -6.6°C (20°F) - The oil control valve coil temperature must be less than 140°C (284°F) - Engine speed must be at least 600 to 1000 rpm to achieve minimum oil pressure. - Battery voltage must be at least 10 volts - And there must be no camshaft or crankshaft sensor faults, engine timing faults, or oil control valve faults First we will examine variable valve timing enabling conditions, and then we will take a closer look at the inputs and outputs of the system: - Accelerator pedal position sensor - Oil temperature sensor - Map sensor - Intake cam sensor - Exhaust cam sensor - Crankshaft sensor - GPEC1 - Exhaust phaser oil control valve - Intake phaser oil control valve - Inputs - Engine control module - Outputs - Sensed battery voltage A minimum oil temperature is required to enable variable valve timing operation. Oil temperature and viscosity also have an impact on the operation of variable valve timing after start-up. Oil is used to control the movement of the camshafts. An incorrect oil viscosity could adversely affect the operation of the system or even render the system inoperative. It may even set a fault code. The accelerator pedal position sensor indicates how far the driver wants to open the throttle plate. The GPEC1 calculates an initial camshaft set point based on whether the accelerator pedal is at part throttle or wide open throttle. The MAP sensor provides information regarding engine load. Sensed battery voltage provides information regarding current system voltage. Sensed battery voltage must be at least 10 volts in order for the oil control valves to function properly. This information allows the GPEC1 to adjust camshaft timing to achieve the best fuel economy, the best engine performance or a combination of both. The hall-effect crankshaft sensor provides RPM information and determines when the number one piston is approaching Top Dead Center. The sensor generates a signal as the tone wheel, attached to the crankshaft, rotates. The tone wheel has 60 teeth minus two. When the gap, created by the missing teeth passes by the sensor, a signal is produced that indicates the number one piston is at Top Dead Center. The GPEC1 uses crankshaft sensor data along with camshaft data to determine the actual position of the camshaft. There are two hall-effect camshaft sensors on engines equipped with variable valve timing. The GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of the camshaft. The GPEC1 individually controls each valve. It sends a pulse width modulated signal to move a spool within the outer casing of the valve. Depending upon spool movement, oil is directed through the passages to advance or retard cam timing. The oil control valve also has a special cleaning strategy at Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Valve Timing Solenoid - Description > Page 1606 key-on. The cleaning strategy is known as "debris crush mode". At key-on the GPEC1 cycles the oil control valve on and off several (5) times to crush any debris in the oil control valve and prevent the spool valve from sticking. In non operating condition, the camshaft stays in lockpin position of cam phases. This is 120 degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust camshaft. There are two oil control valves. One valve directs oil to the intake cam phaser, the other valve directs oil to the exhaust cam phaser. The valves are designed and function in the same manner. The outer casing of each oil valve has five oil passages. A passage for pressurized supply oil. A passage to the advance chamber of the cam phaser. A passage to the retard chamber of the cam phaser. A passage for oil return from the advance chamber of the cam phaser. A passage for oil return from the retard chamber of the cam phaser. Oil flows through the passages and applies pressure to the cam phasers to change cam timing. There are two cam phasers. One phaser controls the position of the intake camshaft. The other phaser controls the position of the exhaust camshaft. The phasers consist of a sprocket, a rotor vane, and a housing or stator. The exhaust cam phaser also consists of a front bushing and spring. We will discuss the purpose and function of the bushing and spring later. The housing is bolted and permanently fixed to the camshaft sprocket, while the rotor vane is bolted and permanently fixed to the camshaft. With this design, any movement of the rotor vane in relation to the housing will also move the camshaft. The phaser and sprocket are serviced as an assembly. Camshaft and crankshaft sensors provide feedback to the GPEC1 regarding the actual position of the camshafts. The GPEC1 then compares the actual camshaft positioning with desired positioning. If the desired positioning is not achieved within a specified time, during the second key cycle a trouble code is set. There are six new diagnostic trouble codes available to help you determine if the control circuit from the GPEC1 to the oil control valve is intact and operating properly. The codes identify whether the control circuit is open, shorted to ground, or shorted to power. Three trouble codes are related to intake camshaft positioning, the other three codes are specific to exhaust camshaft positioning. The oil control valve contains both electrical and mechanical components. It is electrically controlled by the GPEC1. The electrical current that energizes the coil results in mechanical motion of the spool valve. It is possible to verify both the electrical and mechanical operation of the valve. The oil control valve consists of a coil that is energized to move a spool within an outer casing. The condition of the coil can be tested with a Digital Volt Ohmmeter or DVOM. With the DVOM set to measure resistance, check the coil for an open, a short to ground, or excessive resistance. The correct resistance value of the coil is between 6 and 8 ohms. The mechanical operation of the oil control valve can be tested using actuator commands on the scan tool. Remove the oil control valve, then navigate to the actuator menu and select the oil control valve. Use commands to activate the valve and watch as the spool valve moves back and forth inside the casing. Because the cam phasers are hydraulically operated by engine oil, the condition of the oil is very important. The oil must be of the correct viscosity, not obstructed by debris, to maintain correct pressure. Maintaining the correct oil viscosity is critical to the operation of the variable valve timing system. The wrong oil viscosity may cause the variable valve timing to malfunction and trouble codes to set. The correct oil viscosity for this system is 5W20. Oil must be clean, unobstructed and free to flow through the variable valve timing system. Oil could become obstructed in oil passages located in the cylinder head, cylinder block, or even in the oil screen. In the event oil flow is obstructed, further diagnosis or disassembly may be required to pin point the source of the obstruction. The variable valve timing system relies on oil pressure to advance or retard the position of the camshaft. Insufficient oil pressure will adversely affect the operation of variable valve timing. The minimum oil pressure for this system is 15 psi at normal operating temperature. Though not directly used to change camshaft positioning, the oil screen is an important component of the variable valve timing system. It helps to remove debris going to the variable valve timing components. The oil screen is located in the cylinder block, immediately below the cylinder head. Oil must pass through the oil screen before entering the oil control valve. The cylinder head must be removed to service the oil screen. The intention is not to service the oil screen during vehicle life. How the cam phaser works. The cam phaser assembly has eight separate chambers; four advance chambers and four retard chambers. When camshaft advance is requested, oil enters all four advance chambers and exerts force on the rotor vane. Because the rotor vane is bolted to the camshaft, the entire camshaft profile moves along with the rotor vane. At the same time, oil is forced out of the retard chambers. When camshaft retard is requested oil enters the retard chambers to move the camshaft in the opposite direction. There is a lock pin on one side of the rotor vane that fits inside a recessed area in the housing. The lock pin ensures that the default position of the intake cam phaser is 120 crankshaft degrees full retard and the default position of the exhaust cam phaser is 120 crankshaft degrees full advance. When the engine is turned off, rotational force and inertia move the intake camshaft and rotor vane toward the retard position. The exhaust cam phaser includes a spring and bushing to work against the rotational force of the engine, allowing the exhaust cam phaser to lock in the fully advanced position. Under most conditions the cam phasers are returned to lock pin position when the engine is turned off. In the unique condition of an engine stall, which abruptly shuts off the engine, the cam phasers may not return to the lock pin position. In this case, the phasers will return to the lock pin position at the next start-up. Lock pin position is the most ideal cam timing for idle stability. When engine rpm exceeds approximately 600 to 1000 rpm, oil pressure unlocks the pins and variable valve timing resumes. Once enabling conditions are met, the GPEC1 uses input from sensors to calculate optimum valve timing. There are four preprogrammed modes from which the GPEC1 bases initial valve timing. - Starting - Idle or Part throttle - Wide open throttle - Limp-in or Default From each preprogrammed mode, the GPEC1 adjusts valve timing based on operating conditions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Valve Timing Solenoid - Description > Page 1607 GPEC1 has calculated optimum intake valve timing of 112 degrees after Top Dead Center and optimum exhaust valve timing of 97 degrees before Top Dead Center. The GPEC1 pulse width modulates the oil control valves to advance or retard the camshaft to their desired location. The spool valve inside the intake oil control valve is energized and moves to allow pressurized oil into the advance chambers of the intake cam phaser. At the same time, the spool valve inside the exhaust oil control valve is energized and moves to allow pressurized oil into the retard chambers of the exhaust cam phaser. Oil enters the advance chambers of the intake phaser and the retard chambers of the exhaust phaser. Oil pressure releases the lock pin from its locked position and pushes against the rotor vane. Both the rotor vanes are moved, advancing the intake camshaft and retarding the exhaust camshaft. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal Variable Valve Timing Solenoid: Service and Repair Variable Valve Timing Solenoid - Removal Front Solenoid 1/1 FRONT SOLENOID 1/1 1. Disconnect negative battery cable. 2. Remove engine cover. 3. Rotate hose clamp out of way. 4. Disconnect oil pressure sensor electrical connector. 5. Remove oil pressure sensor. 6. Disconnect variable valve timing solenoid electrical connector. 7. Remove variable valve timing solenoid mounting bolt. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 1610 8. Pull solenoid straight out of cylinder head. Rear Solenoid 1/2 REAR SOLENOID 1/2 1. Disconnect negative battery cable. 2. Remove engine cover. 3. Disconnect variable valve timing solenoid electrical connector. 4. Remove variable valve timing solenoid mounting bolt. 5. Pull solenoid straight out of cylinder head. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 1611 Variable Valve Timing Solenoid: Service and Repair Variable Valve Timing Solenoid - Installation Front Solenoid 1/1 FRONT SOLENOID 1/1 1. Solenoid for front location 1/1. Note mounting tab location is different between front and rear solenoids. 2. Install solenoid into cylinder head. 3. Install mounting bolt and tighten to 12 Nm (9 ft. lbs.). 4. Install oil pressure sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 1612 5. Connect electrical connector to oil pressure sensor. 6. Connect electrical connector to Variable valve timing solenoid. 7. Connect negative battery cable. 8. Install engine cover. Rear Solenoid 1/2 REAR SOLENOID 1/2 1. Rear variable valve timing solenoid. Note mounting tab location is different between front and rear solenoids. 2. Install solenoid into cylinder head. 3. Install mounting bolt and tighten to 12 Nm (9 ft. lbs.). 4. Connect electrical connector to Variable valve timing solenoid. 5. Connect negative battery cable. 6. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION CHECK Compression Pressure ............................................................................................................................................................. 1172-1551 kPa (170-225 psi) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1616 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove engine cover. 4. Disconnect coil electrical connectors and remove coils. 5. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators such as fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 6. Disconnect injector electrical connectors. 7. Insert compression gauge adaptor 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer CH7059 with cable adaptors to the DRBIII(R). For Special Tool identification, . See: Tools and Equipment 8. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. 9. Repeat the previous step for all remaining cylinders. 10. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 11. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 12. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications CAMSHAFT BEARING CAP M6 Bolts................................................................................................................................................ ...................................................12 Nm (106 in. lbs.) M8 Bolts............................................................ ..........................................................................................................................................30 Nm (22 ft. lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Gear/Sprocket Variable Valve Timing Phaser ............................................................................................................. ..................................................... 59 Nm (44 ft. lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Description and Operation > Variable Valve Timing Assembly - Description Camshaft Gear/Sprocket: Description and Operation Variable Valve Timing Assembly - Description DESCRIPTION The world engine is equipped with Variable Valve Timing (VVT). This system advances and/or retards intake and/or exhaust camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy, and reduce emissions. The camshaft sprockets are integrated with the VVT assemblies and are serviced as an assembly. VVT assemblies are sometimes referred to as camshaft phasers. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Description and Operation > Variable Valve Timing Assembly - Description > Page 1626 Camshaft Gear/Sprocket: Description and Operation Variable Valve Timing Assembly - Operation OPERATION The Variable Valve Timing (VVT) assemblies are actuated with engine oil pressure. The oil flow to the VVT assemblies are controlled by two Oil Control Valves (OCV). There is an OCV and Camshaft Position Sensor (CMP) for each camshaft. The OCV's consist of a Pulse Width Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through the spool valve into the VVT assemblies. The VVT assembly consists of a rotor, stator, and sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected to the camshaft. Oil flow in to the VVT assembly rotates the rotor with respect to the stator, thus rotating the camshaft with respect to the timing chain. Thus, the VVT assemblies change valve timing by changing the relationship between the camshaft and the timing chain. An infinitely variable valve timing position can be achieved within the limits of the hardware. The CMP monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Variable Valve Timing Assembly - Removal Camshaft Gear/Sprocket: Service and Repair Variable Valve Timing Assembly - Removal REMOVAL NOTE: Camshaft phaser and camshaft sprocket are supplied as an assembly, do not attempt to disassemble. 1. Remove camshaftsSee: Camshaft/Service and Repair/Removal and Replacement/Camshaft Removal. 2. Remove camshaft phaser (2) retaining bolt while holding the camshaft in place with a wrench (1) on the camshaft flats. 3. Remove phaser (2) assembly from camshaft. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Variable Valve Timing Assembly - Removal > Page 1629 Camshaft Gear/Sprocket: Service and Repair Variable Valve Timing Assembly - Installation INSTALLATION CAUTION: Do not use an impact wrench to tighten camshaft sprocket bolts. Damage to the camshaft-to-sprocket locating dowel pin and camshaft phaser may occur. 1. Install phaser (2) assembly on camshaft. NOTE: Make sure the dowel is seated in the dowel hole and not in a oil feed hole. The dowel hole is larger than the 4 oil feed holes. 2. Install phaser retaining bolt. Hold camshaft in place with a wrench (1) and tighten bolt to 59 Nm (44 ft. lbs.). 3. Install camshaftsSee: Camshaft/Service and Repair/Removal and Replacement/Camshaft - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation > Camshaft - Description Camshaft: Description and Operation Camshaft - Description DESCRIPTIONS Both camshafts have five bearing journal surfaces and two cam lobes per cylinder. The two front journals are larger to allow for feeding oil to the variable valve timing (VVT) camshaft phasers. Flanges on the third smaller journal control camshaft end play. At the rear of each camshaft is an integral cam sensor target. CAMSHAFT BEARING CAPS The front cam bearing cap spans both camshafts, and includes dowels for precise alignment. The front exhaust camshaft journal has a select fit bearing insert. This bearing is required to seal the oil passage to the camshaft phaser, because a portion of the lower bearing saddle is machined away for head bolt access. The select fit is required to minimize bearing clearance and oil leakage. An exhaust bearing grade (1,2,or 3) is stamped into the front bearing cap adjacent to the exhaust cam journal. The bearings are also marked with the corresponding grade markings. If the bearing is replaced, the same grade must be used. Due to the unique purpose of this bearing, it may appear to have uneven wear patterns (1). Maximum wear of 0.05 mm (.002 in.) is acceptable. Unless the wear is excessive it is no cause for concern and the bearing should not be replaced. Cam bearing inspection should not be the sole reason for removal of the exhaust camshaft. The upper cam bearing may be replaced if the front bearing cap is removed. The lower cam bearing should be replaced if the camshaft is removed due to a failure of a component within the cylinder head. The front intake cam journal has a full lower bearing saddle, and therefore, no bearing insert is required. All small bearing caps have a formed-in arrow to assist in assembly. All small bearing cap arrows must point towards the center of the cylinder head. The small bearing caps are marked for position during the manufacturing process, and must be reinstalled in their original position. The #1 small cap includes a passage to direct oil from the cylinder head oil gallery to the #1 small bearing journal, and into the camshaft as well. The hollow camshaft then distributes oil to the remainder of the small journals. Oil flowing out of each cam journal lubricates the valve tappets. The #3 small cap is machined at the front and rear face to control camshaft end-play. This cap has dowels for precise alignment. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Description and Operation > Camshaft - Description > Page 1634 Camshaft: Description and Operation Camshaft - Operation OPERATION The camshaft is driven by the crankshaft via drive sprockets and a chain. The camshaft has precisely machined lobes to provide accurate valve timing and duration. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures Camshaft: Procedures Measuring Camshaft End Play MEASURING CAMSHAFT END PLAY 1. Using a suitable tool, move camshaft as far rearward as it will go. 2. Zero dial indicator. 3. Move camshaft as far forward as it will go. 4. Record reading on dial indicator. For end play specification, See: Specifications/Engine Specifications. 5. If end play is excessive, check cylinder head and camshaft for wear; replace as necessary. Camshaft - Cleaning CLEANING Clean camshafts with a suitable solvent. Camshaft - Inspection INSPECTION 1. Inspect camshaft bearing journals for damage. If journals are damaged, check the cylinder head for damage. Also check cylinder head oil holes for clogging. 2. Check the cam lobe and bearing surfaces for abnormal wear and damage. Replace camshaft if defective. NOTE: If camshaft is replaced due to lobe wear or damage, always replace the lash buckets. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1637 Camshaft: Removal and Replacement Camshaft - Removal REMOVAL 1. Remove engine cover (1) by pulling upward. 2. Disconnect and isolate the negative battery cable. 3. Remove cylinder head cover See: Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal. 4. Raise and support the vehicle See: Maintenance/Vehicle Lifting/Service and Repair. 5. Remove the frame cover portion of the right splash shield See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 6. Rotate engine to TDC (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1638 7. Make sure camshaft timing marks (3) are in line with the cylinder head cover sealing surface. 8. Mark the chain link corresponding to timing marks (1) with a paint marker. 9. Remove timing tensioner plug (1) from front cover. 10. Insert small allen wrench through timing tensioner plug hole and lift ratchet (2) upward to release the tensioner and push allen wrench inward. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1639 Leave the allen wrench installed during the remainder of this procedure. 11. Insert Locking Wedge 9701 (1) between camshaft phasers. 12. Lightly tap Locking Wedge 9701 (2) into place until it will no longer sink down. NOTE: Camshaft bearing caps should have been marked during engine manufacturing. For example, number one exhaust camshaft bearing is marked "E1>". CAUTION: DO NOT use a number stamp or a punch to mark camshaft bearing caps. Damage to bearing caps could occur. 13. Using a permanent ink or paint marker, identify location and position on each camshaft bearing cap. 14. Remove the front camshaft bearing cap. 15. Slowly remove the remaining intake and exhaust camshaft bearing cap bolts one turn at a time. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1640 16. Remove intake camshaft (1) by lifting the rear of the camshaft upward. 17. Rotate the camshaft while lifting out of the front bearing cradle. 18. Lift the timing chain (2) off the sprocket (1). 19. Remove exhaust camshaft. 20. Secure timing chain with wire so that it does fall into the timing chain cover. Camshaft - Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1641 1. The front camshaft bearing cap (1) is numbered (2) either one, two, or three, this corresponds to the select fit front exhaust camshaft bearing to use. 2. Install the corresponding select fit front exhaust camshaft bearing (1). 3. Oil all of the camshaft journals with clean engine oil. 4. Install camshaft phasers on camshafts if removed See: Camshaft Gear/Sprocket/Service and Repair/Variable Valve Timing Assembly - Installation . 5. Install timing chain onto exhaust cam sprocket making sure that the timing marks (1) on the sprocket and the painted chain link are aligned. 6. Position exhaust camshaft and on bearing journals in the cylinder head. 7. Align exhaust cam timing mark (3) so it is in line with the cylinder head cover sealing surface (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1642 8. Install intake camshaft by raising the rear of the camshaft upward and roll the sprocket into the chain. 9. Align the timing marks (1) on the intake cam sprocket with the painted chain link. 10. Position the intake camshaft into the bearing journals in the cylinder head. 11. Verify that the timing marks (1) are aligned on both camshafts and that the timing marks (3) are facing each other and are in line with the cylinder head cover sealing surface (2). CAUTION: Install the front intake and exhaust camshaft bearing cap last. Ensure that the dowels are seated and follow torque sequence or damage to engine could result. NOTE: If the front camshaft bearing cap is broken, the cylinder head MUST be replaced. 12. Install intake and exhaust camshaft bearing caps and slowly tighten bolts to 9.5 Nm (85 in. lbs.) in the sequence shown. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1643 NOTE: Verify that the exhaust bearing shells are correctly installed, and the dowels are seated in the head, prior to torquing bolts. 13. Install the front intake and exhaust bearing cap and tighten bolts to 25 Nm (18 ft. lbs.) in the sequence shown. 14. Verify that all timing marks (1,3) are aligned. 15. Remove allen wrench from timing chain tensioner. 16. Remove Locking Wedge 9701 (1) by pulling straight upward on pull rope. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1644 17. Apply MOPAR(R) thread sealant to timing tensioner plug (1) and Install. 18. Rotate the crankshaft CLOCKWISE two complete revolutions until the crankshaft is repositioned at the TDC position. 19. Verify that the camshafts timing marks (3) are in the proper position and in line with the cylinder head cover sealing surface. If the marks do not line up, the timing chain is not correctly installed. 20. Install right splash shield See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 21. Remove RTV from gasket (1). 22. Inspect cylinder head cover gaskets (1,2) for damage. If no damage is present, gaskets can be re-installed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1645 23. Install cylinder head coverSee: Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Installation. 24. Connect negative battery cable. 25. Fill cooling systemSee: Cooling System/Service and Repair. 26. Fill with oil. 27. Operate engine until it reaches normal operating temperature. Check oil and cooling systems for correct fluid levels. 28. Install engine cover (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Tappet(s) - Removal Lifter / Lash Adjuster: Service and Repair Valve Tappet(s) - Removal REMOVAL NOTE: This procedure is for in-vehicle service with camshafts installed. NOTE: Camshaft tappets must be replaced if cylinder head or camshafts are replaced. 1. Remove cylinder head coverSee: Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal. 2. Remove camshaftsSee: Camshaft/Service and Repair/Removal and Replacement/Camshaft - Removal. 3. Remove camshaft tappets (1). 4. Repeat removal procedure for each camshaft tappet (1). 5. If reusing, mark each camshaft bucket for reassembly in original position. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Valve Tappet(s) - Removal > Page 1650 Lifter / Lash Adjuster: Service and Repair Valve Tappet(s) - Installation INSTALLATION NOTE: If reinstalling original tappets they must go back in their original location or engine damage could result. 1. Apply a light coat of clean engine oil to camshafts tappets (1) prior to assembly. 2. Install camshaft tappets (1) into cylinder head. 3. Repeat installation procedure for each camshaft tappet. 4. Install camshaftsSee: Camshaft/Service and Repair/Removal and Replacement/Camshaft Installation. NOTE: If installing new tappets, the valve lash procedure must be performed. 5. Install cylinder head coverSee: Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications CONNECTING ROD Bearing Clearance................................................................................................................................ .......................0.032 - 0.060 mm (0.0012 - 0.0023 in.) Wear Limit....................................................... .....................................................................................................................................0.070 mm (0.0027 in.) CONNECTING ROD BEARING SELECTION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1655 Connecting Rod Bearing: Service and Repair CONNECTING ROD - FITTING There are three different sizes of rod bearings available. Connecting rod bearing identification (4) can be found on the nose of the crankshaft (3). Use the table below for proper bearing selection. CONNECTING ROD BEARING SELECTION 1. For measuring connecting rod bearing clearance procedure and use of PlastigageSee: Service and Repair/Procedures/Measuring Bearing Clearance Using Plastigage. For bearing clearance refer to Engine Specifications. See: Specifications/Engine Specifications. NOTE: The rod bolts should not be reused. 2. Before installing the NEW rod bolts the threads and under the bolt head should be oiled with clean engine oil. 3. Install each bolt finger tight then alternately torque each bolt to assemble the cap properly. 4. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values:CAUTION: Do not use a torque wrench for the second step. - Tighten the bolts to 27 Nm (20 ft. lbs.). - Tighten the connecting rod bolts an additional 90°. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1656 5. Using a feeler gauge, check connecting rod side clearance. Refer to clearance specifications See: Specifications/Engine Specifications. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications CONNECTING ROD Connecting Rod Journal Diameter Journal Grade 1.................................................................................................................................... ..........................................47.966 - 47.972 mm (1.8884 - 1.8886 in.) 2............................................... ...............................................................................................................................47.960 - 47.966 mm (1.8884 - 1.8881 in.) 3................................................................................................................... ...........................................................47.954 - 47.960 mm (1.8879 - 1.8881 in.) Rod Journal- Taper (Max).................................................................................................................... .................................................0.005 mm (0.0001 in.) Side Clearance..................................................................................................................................... ...........................0.1 - 0.25 mm (0.0039 - 0.00098 in.) Wear Limit....................................................... .......................................................................................................................................0.27 mm (0.0106 in.) Connecting Rod Cap-Bolts...............................................................................................................................20 Nm plus 90° turn (15 ft. lbs. plus 90° turn) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1660 Connecting Rod: Description and Operation DESCRIPTION Turbocharged Engine The pistons are made of a cast aluminum alloy. The pistons have floating pins attached to forged connecting rods. The piston pin is offset 0.8 mm (0.0314 in.) towards the thrust side of the piston. The connecting rods are a cracked cap design and are not repairable. The piston with rings, connecting rod and piston pin are serviced as an assembly. Non - Turbocharged Engine The pistons are made of a cast aluminum alloy. The pistons have pressed-in pins attached to forged connecting rods. The piston pin is offset 0.8 mm (0.0314 in.) towards the thrust side of the piston. The connecting rods are a cracked cap design and are not repairable. The piston with rings, connecting rod and piston pin are serviced as an assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures Connecting Rod: Procedures Piston and Bore Measurement PISTON and BORE MEASUREMENT Turbocharged Engine NOTE: Pistons and cylinder bores should be measured at normal room temperature, 21°C (70°F). Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin. 1. Measurement should be taken approximately 22.5 mm (0.886 in.) from the bottom of the skirt. NOTE: Correct piston to bore clearance must be established in order to assure quiet and economical operation. 2. Cylinder bores should be measured halfway down the cylinder bore and transverse (measurement location B) to the engine crankshaft center line shown. Refer to for Engine Specifications See: Specifications/Engine Specifications. Non - Turbocharged Engine NOTE: Pistons and cylinder bores should be measured at normal room temperature, 21°C (70°F). Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin. 1. Measurement should be taken approximately 17 mm (0.669 in.) from the bottom of the skirt. NOTE: Correct piston to bore clearance must be established in order to assure quiet and economical operation. 2. Cylinder bores should be measured halfway down the cylinder bore and transverse (measurement location B) to the engine crankshaft center line shown. Refer to for Engine Specifications See: Specifications/Engine Specifications. Piston Selection PISTON SELECTION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 1663 The pistons are select fit to each bore. There are three different grades of pistons available; A, B, and C. The piston identification (2) is located in the middle of the block on the right side of the engine. The bore identification starts at the top and reads downward. Bore #1 is at the top and bore #4 is at the bottom. The piston, rings and rod are serviced as an assembly, after determining what size piston is needed, See: Connecting Rod Bearing/Service and Repair to determine correct rod bearing size. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 1664 Connecting Rod: Removal and Replacement Piston and Connecting Rod - Removal REMOVAL 1. Drain engine oil (2). NOTE: Pistons, rings, and rods are serviced as an assembly. CAUTION: To maintain engine balance, 1, 3, or 4 pistons can be replaced. If 2 pistons are replaced, the engine will be out of balance. 2. Remove engine See: Service and Repair/Removal and Replacement/Engine - Removal. 3. Place engine on a suitable stand. 4. Remove cylinder head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. 5. Remove oil pan (1)See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Removal. 6. Remove oil filter (1). 7. Remove balance shaft assembly. 8. Remove ladder frame. NOTE: Remove any carbon build up and clean debris from cylinder prior to piston removal to avoid scratching piston skirts. 9. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 1665 10. Rotate crankshaft so that each connecting rod is centered in cylinder bore. 11. Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods, as damage to connecting rod could occur. CAUTION: Care must be taken not to damage the fractured rod and cap joint surfaces, as engine damage may occur. 12. Remove connecting rod bolts and cap. CAUTION: Do not reuse connecting rod bolts. These are one-time-use bolts and reuse could result in engine failure. CAUTION: On turbocharged engines care must be taken not to damage the oil jets when removing piston and rod assemblies. 13. Carefully push each piston and rod assembly out of cylinder bore. Re-install bearing cap on the mating rod. 14. Repeat procedure for each piston and connecting rod assembly. Piston and Connecting Rod - Installation INSTALLATION 1. Install piston rings on piston See: Piston Ring/Service and Repair/Removal and Replacement/Piston Ring(s) - Installation. 2. Before installing pistons and connecting rod assemblies into the bore, be sure that top compression ring gap (1) and the second compression ring gap (3) are staggered so that neither is in line with oil ring rail gap. 3. Before installing the ring compressor, make sure the oil ring expander ends are butted (1) and the rail gaps (2,4) located as shown above. As viewed from the top of the piston. 4. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston. Be sure position of rings does not change during this operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 1666 5. The directional arrow stamped on the piston should face toward the front of the engine. 6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Lubricate connecting rod journal with clean engine oil. NOTE: There are three different size rod bearings, perform rod bearing selection procedure. NOTE: The rod bearing sizes are indicated on the nose of the crankshaft. CAUTION: On turbocharged engines, care must be taken not to damage the oil jets when installing piston and rod assemblies. 7. Install connecting rod upper bearing half into connecting rod. 8. Install ring compressor (3). 9. Tap the piston (1) down in cylinder bore, using a hammer handle (2). At the same time, guide connecting rod into position on connecting rod journal. NOTE: The connecting rod cap bolts should NOT be reused. 10. Install connecting rod lower bearing half into connecting rod cap. Install connecting rod cap. 11. Install NEW connecting rod bolts finger tight then alternately torque each bolt to assemble the cap properly. 12. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values:CAUTION: Do not use a torque wrench for the second step. Turbocharged Engines - Tighten the bolts to 25 Nm (18 ft. lbs.). - Tighten the connecting rod bolts an additional 90°. Non - Turbocharged Engines - Tighten the bolts to 20 Nm (15 ft. lbs.). - Tighten the connecting rod bolts an additional 90°. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 1667 13. Using a feeler gauge, check connecting rod side clearance. See: Specifications/Engine Specifications for connecting rod side clearance. 14. Install the ladder frameSee: Service and Repair/Removal and Replacement/Ladder Frame Installation. 15. Install oil pump/Balance Shaft Carrier Assembly See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement 16. Install oil pan See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Installation. 17. Install cylinder head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Installation. 18. Install engine on dolly. 19. Connect transaxle assembly to engine. 20. Install engineSee: Service and Repair/Removal and Replacement/Engine - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications MAIN BEARING Main Bearing Journal Diameter Journal Grade 0.................................................................................................................................... ..........................................51.985 - 51.988 mm (2.0466 - 2.0467 in.) 1............................................... ...............................................................................................................................51.982 - 51.985 mm (2.0465 - 2.0466 in.) 2................................................................................................................... ...........................................................51.979 - 51.982 mm (2.0464 - 2.0465 in.) 3.............................. ................................................................................................................................................51.976 51.979 mm (2.0462 - 2.0464 in.) 4....................................................................................................... .......................................................................51.973 - 51.976 mm (2.0461 - 2.0462 in.) Journal Out-of-Round (Max.)................................................................................................................ ................................................0.005 mm (0.0001 in.) Journal Taper (Max.)........................................ .....................................................................................................................................0.006 mm (0.0002 in.) End Play............................................................................................................................ ..............................................0.05 - 0.25 mm (0.0019 - 0.0098 in.) Wear Limit.................................... ..........................................................................................................................................................0. 30 mm (0.0118 in.) Main Bearing Diametrical Clearance..........................................................................................................................0.028 0.048 mm (0.0011 - 0.0018 in.) Main Bearing Diametrical Clearance (Max).........................................................................................................................................0.058 mm (0.0022 in.) Main Bearing Bore Diameter 1............................................................................................................. .................................................................56.000 - 56.006 mm (2.2047 - 2.2049 in.) 2........................ ......................................................................................................................................................56.0 06 - 56.012 mm (2.2049 - 2.2051 in.) 3................................................................................................ ..............................................................................56.012 - 56.018 mm (2.2051 - 2.2054 in.) Main Bearing Bore Diameter Taper (Max.)........................................................................................................................................0.0082 mm (0.0003 in.) Lower Main Bearing Selection: Upper Main Bearing Selection: MAIN BEARING CAP Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1671 CAUTION: Before tightening bolts, you must identify the bolt head to obtain the correct torque value. Failure to identify the bolts correctly, could result in improperly tightened bolts which could result in engine damage. If your bolt heads look like this (1,2), use the following torque specifications: Tighten bolts using a three step method, in the sequence shown. Tighten bolts to............................. .............................................................................................................................................................. .15 Nm (11 ft. lbs.) Tighten bolts to...................................................................................................... ......................................................................................27 Nm (20 ft. lbs.) Rotate an additional.......... .............................................................................................................................................................. ....................................45°. If your bolt heads do not look like this (1,2), use the following torque specifications: Tighten bolts using a three step method, in the sequence shown. Tighten bolts to............................. .............................................................................................................................................................. .15 Nm (11 ft. lbs.) Tighten bolts to...................................................................................................... ......................................................................................45 Nm (33 ft. lbs.) Rotate an additional.......... .............................................................................................................................................................. ....................................45°. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1672 Crankshaft Main Bearing: Service and Repair MAIN BEARING SELECTION NOTE: There are three different possibilities for the upper main bearings and five different lower main bearings. The upper and lower bearing shells are not interchangeable. The lower main bearing identification (2) is stamped in the nose of the crankshaft (3). There are 5 different bearing sizes available 0 through 4. The upper main bearing shell identification (1) is located in the middle of cylinder block on the right side of the engine. There are three different size Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1673 bearings available. The bearing class is read downward from top and corresponds to the front journal to the rear journal on the bottom. UPPER MAIN BEARING SELECTION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications CRANKSHAFT Main Bearing Journal Diameter Journal Grade 0.................................................................................................................................... ..........................................51.985 - 51.988 mm (2.0466 - 2.0467 in.) 1............................................... ...............................................................................................................................51.982 - 51.985 mm (2.0465 - 2.0466 in.) 2................................................................................................................... ...........................................................51.979 - 51.982 mm (2.0464 - 2.0465 in.) 3.............................. ................................................................................................................................................51.976 51.979 mm (2.0462 - 2.0464 in.) 4....................................................................................................... .......................................................................51.973 - 51.976 mm (2.0461 - 2.0462 in.) Journal Out-of-Round (Max.)................................................................................................................ ................................................0.005 mm (0.0001 in.) Journal Taper (Max.)........................................ .....................................................................................................................................0.006 mm (0.0002 in.) End Play............................................................................................................................ ..............................................0.05 - 0.25 mm (0.0019 - 0.0098 in.) Wear Limit.................................... ..........................................................................................................................................................0. 30 mm (0.0118 in.) Main Bearing Diametrical Clearance..........................................................................................................................0.028 0.048 mm (0.0011 - 0.0018 in.) Main Bearing Diametrical Clearance (Max).........................................................................................................................................0.058 mm (0.0022 in.) Main Bearing Bore Diameter 1............................................................................................................. .................................................................56.000 - 56.006 mm (2.2047 - 2.2049 in.) 2........................ ......................................................................................................................................................56.0 06 - 56.012 mm (2.2049 - 2.2051 in.) 3................................................................................................ ..............................................................................56.012 - 56.018 mm (2.2051 - 2.2054 in.) Main Bearing Bore Diameter Taper (Max.)........................................................................................................................................0.0082 mm (0.0003 in.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures Crankshaft: Procedures Crankshaft - Inspection INSPECTION The crankshaft main journals should be checked for excessive wear, taper and scoring. Limits of taper on any crankshaft main journals should be held to 0.006 mm (0.00024 in.). Limits of taper on any crankshaft rod journals should be held to 0.005 mm (0.0002 in.). DO NOT nick crank pin or bearing fillets. Limits of out of round on any crankshaft journals should be held to 0.005 mm (0.0002 in). DO NOT nick crank pin or bearing fillets. Measuring Crankshaft End Play MEASURING CRANKSHAFT END PLAY 1. Mount a dial indicator (2) to front of engine with the locating probe on nose of crankshaft (1). 2. Move crankshaft all the way to the rear of its travel. 3. Zero the dial indicator. 4. Move crankshaft all the way to the front and read the dial indicator. See: Specifications/Engine Specifications for end play specification. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1679 Crankshaft: Removal and Replacement Crankshaft - Removal REMOVAL NOTE: Crankshaft can not be removed when engine is in vehicle. 1. Remove engine assembly from vehicle See: Service and Repair/Removal and Replacement/Engine - Removal. 2. Separate transaxle from engine. 3. Remove flex plate/flywheel (1). 4. Remove crankshaft rear oil seal See: Seals and Gaskets/Crankshaft Main Bearing Seal/Service and Repair/Rear Crankshaft Oil Seal - Removal. 5. Remove engine from cradle 6710A (11) and mount engine on a suitable repair stand. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1680 6. Drain engine oil (2). 7. Remove oil filter (1). 8. Remove crankshaft vibration damper (2)See: Harmonic Balancer - Crankshaft Pulley/Service and Repair/Vibration Damper - Removal. 9. Remove water pump pulley (3). 10. Remove engine mount support bracket (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1681 11. Remove the oil pan (2)See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan Removal. 12. Remove timing chain coverSee: Timing Components/Timing Cover/Service and Repair/Engine Timing Cover(s) - Removal. 13. Remove the timing chainSee: Timing Components/Timing Chain/Service and Repair/Removal and Replacement/Timing Chain & Sprockets Removal. 14. Remove balance shaft module. 15. Remove the crankshaft sprocket (1). 16. Remove crankshaft position sensor retaining bolt (1) and remove sensor (2). 17. Remove ladder frameSee: Service and Repair/Removal and Replacement/Ladder Frame - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1682 NOTE: If piston/connecting rod replacement is necessary, remove cylinder head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal . CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to connecting rod could occur. 18. Using a permanent ink or paint marker, identify cylinder number on each connecting rod and cap. 19. Remove all connecting rod bolts and caps. Care should be taken not to damage the fracture rod and cap surfaces. NOTE: Do not reuse connecting rod bolts. 20. Remove main bearing caps. CAUTION: Use extreme care when handling crankshaft. Tone wheel damage can occur if crankshaft is mis-handled. 21. Lift out crankshaft from cylinder block. Do not damage the main bearings or journals when removing the crankshaft. Crankshaft - Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1683 The crankshaft is supported in five main bearings. All upper bearing shells (2) in the crankcase have oil grooves and holes. All lower bearing shells (1) are smooth. Crankshaft end play is controlled by a two piece thrust bearing (3) on the number three main bearing journal. 1. Clean main bearing cap bolt holes with Mopar(R) brake parts cleaner or equivalent and blow out with compressed air. 2. Install the main bearing upper (2) shells with the lubrication groove and oil hole in the engine block. 3. Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots. NOTE: If the crankshaft is sent out for machine work, it must be balanced as an assembly with the target ring installed. 4. Clean crankshaft and target ring with MOPAR(R) Brake Parts cleaner and dry with compressed air to ensure that the crankshaft mating surface and target ring mounting holes are free from oil and lock patch debris. NOTE: Always use NEW mounting screws whether installing original or new target ring. 5. Install NEW mounting screws finger tight starting with the #1 location. Make sure engagement occurs with the shoulder of the screws and mounting hole before starting all other screws. 6. Tighten all mounting screws to 13 Nm (110 in-lbs) in the sequence shown. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1684 NOTE: Lightly apply trans gel to thrust bearings to hold bearings in block. NOTE: The thrust bearings must be installed the notches facing the crankshaft. 7. Install thrust bearings (2) in block (1). CAUTION: Do not get oil on the ladder frame mating surface. It will affect the ability of the RTV to seal the ladder frame to cylinder block. NOTE: Ensure main bearing cap bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not damaged. 8. Oil the bearings and journals. Install crankshaft in engine block. 9. Install lower main bearings (1) into main bearing cap. Make certain the bearing tabs are seated into the bearing cap slots. NOTE: Main bearing caps are stamped 1 - 5 front to rear. Arrows on the caps must point towards the front of the engine. 10. Install main bearing caps to engine block. 11. Before installing the bolts the threads should be clean and dry. 12. Loosely install main bearing cap bolts. 13. To ensure correct thrust bearing alignment, perform the following steps: - Step 1: Rotate crankshaft until number 4 piston is at TDC. - Step 2: Move crankshaft rearward to limits of travel. - Step 3: Then, move crankshaft forward to limits of travel. - Step 4: Wedge an appropriate tool between the rear of the cylinder block and the rear crankshaft counterweight. This will hold the crankshaft in its furthest forward position. CAUTION: There are different sets main bolts supplied with this engine. Each bolt set has a different torque value and engine damage could result if bolts are not torqued correctly. The bolts are not interchangeable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1685 14. If your bolt heads look like this (1,2), go to step 15. If your bolt heads do not look like this (1,2), go to step 16. CAUTION: Before tightening bolts, you must identify the bolt head to obtain the correct torque value. Failure to identify the bolts correctly, could result in improperly tightened bolts which could result in engine damage. 15. Tighten bolts using a three step method, in the sequence shown. - Tighten bolts to 15 Nm (11 ft. lbs.) - Tighten bolts to 27 Nm (20 ft. lbs.) - Rotate an additional 45°. 16. Tighten bolts using a three step method, in the sequence shown. - Tighten bolts to 15 Nm (11 ft. lbs.) - Tighten bolts to 45 Nm (33 ft. lbs.) - Rotate an additional 45°. 17. Remove wedge tool used to hold crankshaft. 18. Check the crankshaft turning torque, it should not exceed 5.6 Nm (50 in. lbs.). 19. Check crankshaft end play See: Procedures. 20. Install connecting rod bearings and caps. Do Not Reuse Connecting Rod Bolts. Tighten connecting rod bolts to 20 Nm + 90° (15 ft. lbs.) + 90° See: Connecting Rod/Service and Repair/Removal and Replacement/Piston and Connecting Rod Installation. 21. Install the ladder frame assemblySee: Service and Repair/Removal and Replacement/Ladder Frame - Installation. 22. Install the balance shaft moduleSee: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement/Engine Oil Pump - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1686 23. Install crankshaft position sensor (2) and tighten bolt (1). 24. Install cylinder head if it was removed See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Installation. 25. Install front crankshaft sprocket (1). 26. Install the timing chain See: Timing Components/Timing Chain/Service and Repair/Removal and Replacement/Timing Chain & Sprockets Installation. 27. Install the timing chain front coverSee: Timing Components/Timing Cover/Service and Repair/Engine Timing Cover(s) - Installation. 28. Install the oil pan See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Installation. 29. Install rear crankshaft oil sealSee: Seals and Gaskets/Crankshaft Main Bearing Seal/Service and Repair/Rear Crankshaft Oil Seal Installation. 30. Install front crankshaft oil sealSee: Seals and Gaskets/Front Crankshaft Seal/Service and Repair/Front Crankshaft Oil Seal - Installation. 31. Install engine mount support bracket (1). 32. Install crankshaft vibration damper (2)See: Harmonic Balancer - Crankshaft Pulley/Service and Repair/Vibration Damper - Installation. 33. Install water pump pulley (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 1687 34. Remove engine from repair stand and install engine lift chain (1). 35. Install crankshaft rear oil seal See: Seals and Gaskets/Crankshaft Main Bearing Seal/Service and Repair/Rear Crankshaft Oil Seal - Installation. 36. Install drive plate/flex plate using new bolts. Tighten bolts to 95 Nm (70 ft. lbs.). 37. Attach transaxle to engine. Tighten bellhousing bolts to 101 Nm (75 ft. lbs.). 38. Install the engine assembly See: Service and Repair/Removal and Replacement/Engine - Installation. 39. Install new oil filter (1) and fill with oil. 40. Fill with coolantSee: Cooling System/Service and Repair. 41. Start engine and check for leaks. 42. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Engine Block Heater - Description Engine Block Heater: Description and Operation Engine Block Heater - Description DESCRIPTION The cartridge type block heater is mounted in a bore at the rear of the block under the coolant adapter. The block heater does not directly contact coolant. It heads the aluminum block. The heater is powered by 110 Volt AC through a power cord and connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Engine Block Heater - Description > Page 1692 Engine Block Heater: Description and Operation Engine Block Heater - Operation OPERATION The block heater element is inserted into a bore in the engine block. When electrical power (110 volt A.C.) is applied to the element, it creates heat. This heat is transferred to the aluminum engine block. This provides easier engine starting and faster warm-up when vehicle is operated in areas having extremely low temperatures. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1693 Engine Block Heater: Testing and Inspection ENGINE BLOCK HEATER TESTING If unit does not operate, trouble can be in either the power cord or the heater element. Test power cord for continuity with a 110-volt voltmeter or 110-volt test light; test heater element continuity with an ohmmeter or 12-volt test light. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater - Removal Engine Block Heater: Service and Repair Engine Block Heater - Removal REMOVAL 1. Remove engine cover. 2. Remove air cleaner inlet. 3. Detach power cord plug from heater. 4. Remove retaining clip (1). Remove block heater assembly (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater - Removal > Page 1696 Engine Block Heater: Service and Repair Engine Block Heater - Installation INSTALLATION 1. Thoroughly clean bore hole. 2. Insert block heater assembly into bore. 3. Install retaining clip. 4. Connect power cord to block heater. 5. Install air intake inlet. 6. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications CRANKSHAFT PULLEY Crankshaft Damper-Bolt....................................................................................................................... ...................................................210 Nm (155 ft. lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Vibration Damper - Removal Harmonic Balancer - Crankshaft Pulley: Service and Repair Vibration Damper - Removal REMOVAL 1. Remove accessory drive belts See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. 2. Install Damper holder 9707 (1). 3. Remove crankshaft damper bolt. 4. Pull damper off crankshaft. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Vibration Damper - Removal > Page 1702 Harmonic Balancer - Crankshaft Pulley: Service and Repair Vibration Damper - Installation INSTALLATION 1. Install crankshaft damper. 2. Apply clean engine oil crankshaft damper bolt threads and between bolt head and washer. Tighten bolt to 210 Nm (155 ft. lbs.). 3. Install accessory drive belts See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications PISTONS Piston Diameter A................................................................................................................................. ............................................87.995 - 88.015 mm (3.4644 - 3.4652 in.) B............................................. ................................................................................................................................88.005 - 88.025 mm (3.4648 - 3.4656 in.) C................................................................................................................... ..........................................................88.015 - 88.035 mm (3.4652 - 3.4659 in.) Clearance to Bore................................................................................................................................. ...............(-0.015) - 0.015 mm ((-0.0006) - 0.0006 in.) Weight.............................................................. ................................................................................................................302 - 312 grams (10.65 11.00 oz.) Land Clearance (Diametrical).............................................................................................. ...........................................0.60 - 0.73 mm (0.0236 - 0.0287 in.) Piston Length.................................. ...........................................................................................................................................................5 1.5 mm (2.028 in.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1706 Piston: Description and Operation DESCRIPTION Turbocharged Engine The pistons are made of a cast aluminum alloy. The pistons have floating pins attached to forged connecting rods. The piston pin is offset 0.8 mm (0.0314 in.) towards the thrust side of the piston. The connecting rods are a cracked cap design and are not repairable. The piston with rings, connecting rod and piston pin are serviced as an assembly. Non - Turbocharged Engine The pistons are made of a cast aluminum alloy. The pistons have pressed-in pins attached to forged connecting rods. The piston pin is offset 0.8 mm (0.0314 in.) towards the thrust side of the piston. The connecting rods are a cracked cap design and are not repairable. The piston with rings, connecting rod and piston pin are serviced as an assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures Piston and Bore Measurement PISTON and BORE MEASUREMENT Turbocharged Engine NOTE: Pistons and cylinder bores should be measured at normal room temperature, 21°C (70°F). Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin. 1. Measurement should be taken approximately 22.5 mm (0.886 in.) from the bottom of the skirt. NOTE: Correct piston to bore clearance must be established in order to assure quiet and economical operation. 2. Cylinder bores should be measured halfway down the cylinder bore and transverse (measurement location B) to the engine crankshaft center line shown. Refer to for Engine Specifications See: Specifications/Engine Specifications. Non - Turbocharged Engine NOTE: Pistons and cylinder bores should be measured at normal room temperature, 21°C (70°F). Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin. 1. Measurement should be taken approximately 17 mm (0.669 in.) from the bottom of the skirt. NOTE: Correct piston to bore clearance must be established in order to assure quiet and economical operation. 2. Cylinder bores should be measured halfway down the cylinder bore and transverse (measurement location B) to the engine crankshaft center line shown. Refer to for Engine Specifications See: Specifications/Engine Specifications. Piston Selection PISTON SELECTION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1709 The pistons are select fit to each bore. There are three different grades of pistons available; A, B, and C. The piston identification (2) is located in the middle of the block on the right side of the engine. The bore identification starts at the top and reads downward. Bore #1 is at the top and bore #4 is at the bottom. The piston, rings and rod are serviced as an assembly, after determining what size piston is needed, See: Connecting Rod Bearing/Service and Repair to determine correct rod bearing size. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1710 Piston: Removal and Replacement Piston and Connecting Rod - Removal REMOVAL 1. Drain engine oil (2). NOTE: Pistons, rings, and rods are serviced as an assembly. CAUTION: To maintain engine balance, 1, 3, or 4 pistons can be replaced. If 2 pistons are replaced, the engine will be out of balance. 2. Remove engine See: Service and Repair/Removal and Replacement/Engine - Removal. 3. Place engine on a suitable stand. 4. Remove cylinder head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal. 5. Remove oil pan (1)See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Removal. 6. Remove oil filter (1). 7. Remove balance shaft assembly. 8. Remove ladder frame. NOTE: Remove any carbon build up and clean debris from cylinder prior to piston removal to avoid scratching piston skirts. 9. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1711 10. Rotate crankshaft so that each connecting rod is centered in cylinder bore. 11. Using a permanent ink or paint marker, identify cylinder number on each connecting rod cap. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods, as damage to connecting rod could occur. CAUTION: Care must be taken not to damage the fractured rod and cap joint surfaces, as engine damage may occur. 12. Remove connecting rod bolts and cap. CAUTION: Do not reuse connecting rod bolts. These are one-time-use bolts and reuse could result in engine failure. CAUTION: On turbocharged engines care must be taken not to damage the oil jets when removing piston and rod assemblies. 13. Carefully push each piston and rod assembly out of cylinder bore. Re-install bearing cap on the mating rod. 14. Repeat procedure for each piston and connecting rod assembly. Piston and Connecting Rod - Installation INSTALLATION 1. Install piston rings on piston See: Piston Ring/Service and Repair/Removal and Replacement/Piston Ring(s) - Installation. 2. Before installing pistons and connecting rod assemblies into the bore, be sure that top compression ring gap (1) and the second compression ring gap (3) are staggered so that neither is in line with oil ring rail gap. 3. Before installing the ring compressor, make sure the oil ring expander ends are butted (1) and the rail gaps (2,4) located as shown above. As viewed from the top of the piston. 4. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston. Be sure position of rings does not change during this operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1712 5. The directional arrow stamped on the piston should face toward the front of the engine. 6. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Lubricate connecting rod journal with clean engine oil. NOTE: There are three different size rod bearings, perform rod bearing selection procedure. NOTE: The rod bearing sizes are indicated on the nose of the crankshaft. CAUTION: On turbocharged engines, care must be taken not to damage the oil jets when installing piston and rod assemblies. 7. Install connecting rod upper bearing half into connecting rod. 8. Install ring compressor (3). 9. Tap the piston (1) down in cylinder bore, using a hammer handle (2). At the same time, guide connecting rod into position on connecting rod journal. NOTE: The connecting rod cap bolts should NOT be reused. 10. Install connecting rod lower bearing half into connecting rod cap. Install connecting rod cap. 11. Install NEW connecting rod bolts finger tight then alternately torque each bolt to assemble the cap properly. 12. Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the following values:CAUTION: Do not use a torque wrench for the second step. Turbocharged Engines - Tighten the bolts to 25 Nm (18 ft. lbs.). - Tighten the connecting rod bolts an additional 90°. Non - Turbocharged Engines - Tighten the bolts to 20 Nm (15 ft. lbs.). - Tighten the connecting rod bolts an additional 90°. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1713 13. Using a feeler gauge, check connecting rod side clearance. See: Specifications/Engine Specifications for connecting rod side clearance. 14. Install the ladder frameSee: Service and Repair/Removal and Replacement/Ladder Frame Installation. 15. Install oil pump/Balance Shaft Carrier Assembly See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement 16. Install oil pan See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Installation. 17. Install cylinder head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Installation. 18. Install engine on dolly. 19. Connect transaxle assembly to engine. 20. Install engineSee: Service and Repair/Removal and Replacement/Engine - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications PISTON RINGS Ring Gap-Top Compression Ring...................................................................................................................................0.15 - 0.30 mm (0.0059 - 0.0118 in.) Wear Limit.................................................................................................... ..............................................................................................0.8 mm (0.031 in.) Ring Gap-2nd Compression Ring...................................................................................................................................0.30 - 0.45 mm (0.0118 - 0.0177 in.) Wear Limit.................................................................................................... ..............................................................................................0.8 mm (0.031 in.) Ring Gap-Oil Control Steel Rails...................................................................................................................................0.20 - 0.70 mm (0.0079 - 0.0276 in.) Wear Limit.................................................................................................... ..............................................................................................1.0 mm (0.039 in.) Ring Side Clearance-Compression Rings.......................................................................................................................0.03 - 0.07 mm (0.1182 - 0.0028 in.) Wear Limit........................................................................................................... .....................................................................................0.10 mm (0.004 in.) Ring Side Clearance-Oil Ring Pack................................................................................................................................0.06 - 0.15 mm (0.0024 - 0.0059 in.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Procedures Piston Ring: Procedures PISTON RING - FITTING 1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 13 mm (0.50 inch) from bottom of cylinder bore and below the bottom of the oil ring travel where cylinder bore has minimal wear. Check gap with feeler gauge. Refer to Engine Specifications.See: Specifications/Engine Specifications NOTE: Ring end gap measurements are sensitive to the ring being square in the bore. Care must be used to avoid tilting the rings in cylinder bores when taking measurements. 2. Check piston ring to groove side clearance. Refer to Engine Specifications.See: Specifications/Engine Specifications CAUTION: Exercise care when using tools on piston. Do not scratch or gouge piston surface or ring grooves as this may cause engine damage. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Procedures > Page 1719 Piston Ring: Removal and Replacement Piston Ring(s) - Removal REMOVAL 1. Using a suitable ring expander, remove upper and intermediate piston rings. 2. Remove the upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston. 3. Clean ring grooves of any carbon deposits. Piston Ring(s) - Installation INSTALLATION NOTE: The identification mark on face of upper and intermediate piston rings must point toward top of piston. CAUTION: Install piston rings in the following order: - Oil ring expander. - Upper oil ring side rail. - Lower oil ring side rail. - No. 2 Intermediate piston ring. - No. 1 Upper piston ring. 1. Install oil ring expander. 2. Install upper side rail first and then the lower side rail. Install the side rails by placing one end between the piston ring groove and the oil ring expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander. NOTE: On normally aspirated engines, the compression rings are marked Y1 for the upper compression ring and Y2 for the second compression ring. These markings must face upward. NOTE: On turbocharged engines, the compression rings are marked "TOP". "TOP" must face upward. 3. Install No. 2 piston ring and then No. 1 piston ring. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Procedures > Page 1720 NOTE: Install the piston rings so the gaps positioned as indicated with the piston viewed from the top. NOTE: Staggering ring gap is important for oil control. 4. Install the oil expander so the ring gap is located in the (1) position. 5. Install the oil ring rails so the ring gap is located in the (2,4) position. 6. Install the second compression ring so the ring gap is located in the (3) position. 7. Install the top compression so the ring gap is located in the (1) position. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Lash Intake.................................................................................................................................................... ..............................0.17 - 0.23 mm (0.006 - 0.009 in.) Exhaust............................................................ ...................................................................................................................0.27 - 0.33 mm (0.010 0.012 in.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1725 Valve Clearance: Adjustments MEASURING VALVE LASH NOTE: The engine must be cold to measure valve lash. 1. Remove engine cover. 2. Remove cylinder head coverSee: Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal. 3. Rotate camshaft so lobes are vertical (1). 4. Check clearance using feeler gauges. 5. Repeat for all tappets and record readings. 6. If clearance was too small, refer to the Clearance too Small procedure. Clearance too Small. 7. If clearance was too large, refer to the Clearance too Large procedure. Clearance too Large. Clearance too Small Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1726 1. Remove camshaftsSee: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Removal. 2. Specification - clearance = change. 3. Decrease tappet thickness by change figure. 4. Install camshafts See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Installation. 5. Verify that valve lash is correct. Clearance too Large 1. Remove camshaftsSee: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Removal. 2. Clearance - specification = change. 3. Increase tappet thickness by change figure. 4. Install camshaftsSee: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Installation. 5. Verify that valve lash is correct. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove lower rear seat cushion. 2. Remove the fuel pump module cover. 3. Disconnect the electrical connector for fuel pump module. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. Turn ignition key to OFF position. 7. Disconnect negative battery cable. 8. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory. The scan tool must be used to erase a DTC. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal Valve Cover: Service and Repair Cylinder Head Cover(s) - Removal REMOVAL 1. Remove engine cover (1) by pulling upward. 2. Disconnect and isolate the negative battery cable. 3. Remove make up air hose (2). 4. Remove PCV hose (5). 5. Disconnect ignition coil electrical connectors (1). 6. Use compressed air to blow dirt and debris off the cylinder head cover prior to removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal > Page 1734 7. Remove cylinder head cover bolts. 8. Remove cylinder head cover from cylinder head. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal > Page 1735 Valve Cover: Service and Repair Cylinder Head Cover(s) - Installation INSTALLATION 1. Install new cylinder head cover gaskets (1,2). 2. Install studs in cover as shown. 3. Clean all RTV from cylinder head See: Service and Repair/Procedures. NOTE: When using RTV, the sealing surfaces must be clean and free from grease and oil. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal > Page 1736 NOTE: When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes. 4. Apply a dot of Mopar(R) engine sealant RTV or equivalent to cylinder head/front cover T-joint (1). 5. Install cylinder head cover assembly to cylinder head and install all bolts, ensuring the studs are located as shown. 6. Tighten bolts in sequence shown using a 2 step torque method as follows: a. Tighten all bolts to 5 Nm (44 in. lbs.). b. Tighten all bolts to 10 Nm (90 in. lbs.). 7. Install ignition coils. Tighten fasteners to 8 Nm (70 in. lbs.). 8. If the PCV valve was removed, tighten PCV valve to 5 Nm (44 in. lbs.). 9. Connect coil electrical connectors (1). 10. Connect PCV hose (5) to PCV valve. 11. Connect make up air hose (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal > Page 1737 12. Connect negative battery cable. 13. Install engine cover (1) by pressing the rear of the cover down first. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures Valve Spring: Procedures INSPECTION 1. Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested for correct load. Discard the springs that do not meet specifications. The following specifications apply to both intake and exhaust valves springs: Valve closed nominal load - 179.5 N ± 9 N @ 35.0 mm (40.35 lbs. ± 2 lbs. @ 1.38 in.). - Valve open nominal load - 364.8 N ± 17 N @ 29.25 mm (82 lbs. ± 3.8 lbs. @ 1.152 in.). 2. Inspect each valve spring for squareness with a steel square and surface plate, test springs from both ends. If the spring is more than 1.5 mm (1/16 inch) out of square, install a new spring. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1742 Valve Spring: Removal and Replacement Cylinder Head Off CYLINDER HEAD OFF 1. With cylinder head removed from cylinder block, place a ball of rags in the combustion chamber. CAUTION: Care must be taken not to damage the tappet bore or engine damage may result. 2. Mark valve tappet location for assembly. 3. Remove valve tappets. 4. Using metric valve keeper tool such as Snap-on(R) GA317 (or equivalent) remover (1) , remove valve keepers with a downward push. 5. Remove retainer and springs. 6. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves, locks and retainers to insure installation in original location. 7. Inspect the valves. See: Procedures. Cylinder Head On CYLINDER HEAD ON 1. Rotate crankshaft until piston is at TDC on compression. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1743 2. Remove cylinder head cover See: Valve Cover/Service and Repair/Cylinder Head Cover(s) Removal. 3. Remove camshaftsSee: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Removal. 4. Mark valve tappet location for assembly. 5. Remove valve tappets. 6. With air hose attached to adapter tool installed in spark plug hole, apply 90-120 psi air pressure. CAUTION: Care must be taken not to damage the tappet bore or engine damage may result. 7. Using metric valve keeper tool (1) such as Snap-on(R) GA317 (or equivalent), and remove valve spring keepers and retainer. 8. Remove valve spring(s). 9. Remove valve stem seal(s) by a using valve stem seal tool. Cylinder Head Off CYLINDER HEAD OFF CAUTION: Care must be taken not to damage the tappet bore or engine damage may result. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1744 1. Coat valve stems with clean engine oil and insert in cylinder head. 2. Install new valve stem seals (3) on all valves using an appropriate sized socket to seat the seal/spring seat. The valve stem seals should be pushed firmly and squarely over valve guide. 3. Install valve springs (2). 4. Install keepers in retainer and place on valve spring. 5. Using metric valve keeper tool such as Snap-on(R) GA317 (or equivalent) installer (2) and remover (1) as a handle, push downward to install keepers. 6. Check the valve spring installed height B after refacing the valve and seat. Make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 38.75 mm (1.525 in.), install a 0.762 mm (0.030 in.) spacer under the valve spring seat to bring spring height back within specification. 7. Install valve tappets. Cylinder Head On CYLINDER HEAD ON CAUTION: Care must be taken not to damage the tappet bore or engine damage may result. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1745 1. Install valve seal/valve spring seat (3) assembly. Push the assembly down with appropriate size socket to seat it onto the valve guide. 2. Install valve spring (2) and retainer (4) with keepers (1). 3. Place the valve keepers in the retainer. Using metric valve keeper tool such as Snap-on(R) GA317 (or equivalent) installer (2) and remover (1) as a handle, install valve keepers with a downward push. 4. Remove air hose and install spark plugs. 5. Install valve tappets. 6. Install camshaftsSee: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Installation. 7. Install cylinder head cover See: Valve Cover/Service and Repair/Cylinder Head Cover(s) - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Description and Operation > Intake and Exhaust Valves - Description Valve: Description and Operation Intake and Exhaust Valves - Description DESCRIPTION The valves are made of heat resistant steel. They have nitrided stems to prevent scuffing. Viton rubber valve stem seals are integral with the spring seats. The valves have a single bead lock keepers to retain the springs. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Description and Operation > Intake and Exhaust Valves - Description > Page 1750 Valve: Description and Operation Intake and Exhaust Valves - Operation OPERATION The four valves per cylinder (two intake and two exhaust) are opened by using direct acting tappets which are actuated by the camshaft. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Description and Operation > Page 1751 Valve: Service and Repair CLEANING Clean all valves thoroughly and discard burned, warped and cracked valves. CAUTION: Due to the small margin on the valves, grinding is not recommended. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation Drive Belt: Description and Operation GAS ENGINE The accessory drive belt (2) is a serpentine type belt that is driven by the crankshaft pulley (6). The belt drives the A/C compressor, generator (3), power steering pump (1) and water pump (7). Belt tension is maintained by an automatic belt tensioner (8). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 1756 Drive Belt: Testing and Inspection ACCESSORY DRIVE BELT VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (1), are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) (2) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for contamination, alignment, glazing, or excessive end play. ACCESSORY DRIVE BELT DIAGNOSIS CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 1757 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures Drive Belt: Procedures CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures > Page 1760 Drive Belt: Removal and Replacement Serpentine Accessory Drive Belt - Removal GAS ENGINE 1. Using a wrench, rotate accessory drive belt tensioner (8) counterclockwise until accessory drive belt (2) can be removed from pulleys (5 and 9). 2. Remove accessory drive belt (2). Serpentine Accessory Drive Belt - Installation GAS ENGINE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures > Page 1761 NOTE: When installing drive belt on the pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulley grooves. 1. Install the accessory drive belt (2) around all the pulleys except for the generator pulley (3). 2. Using a wrench, rotate accessory drive belt tensioner (8) counterclockwise until accessory drive belt (2) can be installed on the generator pulley (3). Release spring tension onto accessory drive belt (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation Drive Belt Tensioner: Description and Operation DESCRIPTION The automatic belt tensioner maintains proper tension on the accessory drive belt. The tensioner pulley can be serviced separately. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Accessory Drive Belt Tensioner - Removal Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner - Removal GAS ENGINE 1. Raise vehicle on hoist. 2. Remove belt splash shield (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Accessory Drive Belt Tensioner - Removal > Page 1767 3. Remove accessory drive belt See: Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. 4. Remove accessory drive belt tensioner mounting bolt. Remove accessory drive belt tensioner (8). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Accessory Drive Belt Tensioner - Removal > Page 1768 Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner - Installation GAS ENGINE 1. Position accessory drive belt tensioner (8) and install mounting bolt (1). Tighten bolt (1) to 24 Nm (212 in. lbs.). 2. Install accessory drive belt See: Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Accessory Drive Belt Tensioner - Removal > Page 1769 3. Install belt splash shield (3). 4. Lower vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Description and Operation > Engine Mounting - Description Engine Mount: Description and Operation Engine Mounting - Description DESCRIPTION The engine mounting system consists of a four-point system utilizing two load-carrying mounts and two torque controlling mounts. The load-carrying mounts are located on each frame rail. The right and left mounts are hydro-elastic mounts. The two torque controlling mounts are attached to a fore/aft member and the front and rear of the engine. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Description and Operation > Engine Mounting - Description > Page 1774 Engine Mount: Description and Operation Engine Mounting - Operation OPERATION The four-point engine mounting system minimizes the transmission of structure-borne engine noise to the passenger compartment. The load-carrying right and left mounts dampen and isolate vertical motion and vibration. The front and rear mount absorb torque reaction forces and torsional vibrations. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal Engine Mount: Service and Repair Engine Mount Insulator - Removal Left REMOVAL 1. Remove air cleaner inlet (2) and air cleaner housing (1). 2. Remove PCM (1). 3. Remove PCM mounting bracket. 4. Disconnect negative cable from battery (3). 5. Support transaxle with a suitable jack. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 1777 6. Remove left mount through bolt (3). 7. Remove left mount bracket to body frame rail fasteners (1). 8. Remove mount. Rear REMOVAL 1. Remove rear mount retaining bolts (4). 2. Remove rear mount through bolt (1). 3. Remove oxygen sensor connector (2) from mount. 4. Remove rear mount (3). Front REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 1778 1. Raise vehicle. 2. Remove fore aft member (3) to mount (4) bolts. 3. Remove mount through bolt (1). 4. Remove fore aft member (3) mounting bolts and remove. 5. Remove front mount (4). Right REMOVAL 1. Remove coolant reservoir (3) and set aside. 2. Remove power steering reservoir (2) and set aside. 3. Remove windshield washer bottle (1). 4. Remove power steering line support bracket (1) from engine mount. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 1779 5. Support transaxle with a block of wood and a suitable jack. 6. Remove engine mount through bolt (4). 7. Remove engine mount bracket bolts (3). 8. Remove engine mount retaining bolts. 9. Remove engine mount. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 1780 Engine Mount: Service and Repair Engine Mount Insulator - Installation Left INSTALLATION 1. Position mount (2) in place. 2. Install left mount to frame rail bolts (1) and torque to 75 Nm (55 ft. lbs.). 3. Install mount through bolt (3) and torque to 100 Nm (74 ft.lbs.). 4. Remove jack. 5. Install PCM mounting bracket. 6. Install PCM (1). 7. Connect negative cable to battery (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 1781 8. Install air cleaner housing (1) and air cleaner inlet (2). Rear INSTALLATION 1. Position rear mount (3). 2. Install rear mount retaining bolts (4) and torque to 50 Nm (37 ft. lbs.). 3. Install rear mount through bolt (1) and torque to 47 Nm (35 ft. lbs.). 4. Install oxygen sensor connector (2) retainer to mount (3). Front INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 1782 1. Position mount (4) and torque bolts to 47 Nm (35 ft. lbs.). 2. Install fore aft member (3) and torque bolts to 100 Nm (74 ft. lbs.). 3. Install mount through bolt (1) and torque to 47 Nm (35 ft. lbs.). 4. Lower vehicle. Right INSTALLATION 1. Position right engine mount (1). 2. Install engine mount retaining bolts and tighten to 75 Nm (55 ft. lbs.). 3. Install engine mount adapter (2) and tighten bolts (3) to 68 Nm (50 ft. lbs.). 4. Install engine mount through bolt (4) and tighten to 88 Nm (65 ft. lbs.). 5. Remove jack. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 1783 6. Install power steering line support bracket (1) at engine mount. 7. Install windshield washer bottle (1). 8. Install power steering reservoir (2). 9. Install coolant reservoir (3). 10. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Accessory Drive Idler Pulley - Removal Idler Pulley: Service and Repair Accessory Drive Idler Pulley - Removal REMOVAL 1. Raise vehicle on hoist. 2. Remove belt splash shield. 3. Remove accessory drive belt See: Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. 4. Remove idler pulley mounting bolt. Remove idler pulley (5 or 9). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Accessory Drive Idler Pulley - Removal > Page 1788 Idler Pulley: Service and Repair Accessory Drive Idler Pulley - Installation INSTALLATION 1. Position pulley (5 or 9) in mounting position. Install idler pulley mounting bolt. Tighten bolt to 48 Nm (35 ft. lbs.). 2. Install accessory drive belt See: Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation. 3. Install belt splash shield. 4. Lower vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications ENGINE OIL PRESSURE At Curb Idle Speed*.............................................................................................................................. ....................................................25 kPa (4 psi. min.) At 3000 rpm...................................................... ............................................................................................................................170 - 550 kPa (25 80 psi.) CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure Engine Oil Pressure: Testing and Inspection Checking Engine Oil Pressure CHECKING ENGINE OIL PRESSURE NOTE: Anytime the oil temperature sensor is removed, it should be replaced with a new sensor. 1. Disconnect and remove oil temperature sensor (1). CAUTION: Threads in cylinder head are British Standard Pipe (BSP). Do not install a NPT threaded adapter, this could crack the cylinder head. 2. Install threaded adapter 9879 (1). 3. Install oil pressure gauge (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure > Page 1795 4. Start engine and record reading on oil pressure gauge (1). CAUTION: If oil pressure is 0 at idle, do not perform the 3000 RPM test 5. If oil pressure is 0 at idle, shut off engine. Check for pressure relief valve stuck open, a clogged oil pick-up screen. 6. Remove oil pan and inspect for debrisSee: Oil Pan/Service and Repair/Engine Oil Pan - Removal. 7. Remove oil pressure relief valveSee: Oil Pump/Oil Pressure Regulator Valve/Service and Repair/Removal and Replacement/Oil Pressure Relief Valve - Removal. and 8. Inspect oil pressure relief valveSee: Oil Pump/Oil Pressure Regulator Valve/Service and Repair/Procedures if damaged replace. 9. If pressure relief valve is ok, replace balance shaft module assemblySee: Oil Pump/Service and Repair/Removal and Replacement/Engine Oil Pump - Removal. 10. After test is complete, remove oil pressure gauge (2) and adapter 9879 (1). 11. Install a new oil pressure temperature sensor (1) and connect electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure > Page 1796 Engine Oil Pressure: Testing and Inspection Checking VVT Oil Pressure CHECKING VVT OIL PRESSURE This test can be used to help diagnose VVT faults. 1. Disconnect and remove oil pressure sensor (1). CAUTION: Threads in block are 1/8"-28 British Standard Pipe (BSP). Do not install a National Pipe Thread (NPT) threaded adapter, this could crack the cylinder block. 2. Install an 1/8-28 BSP male to 1/8-27 female threaded adapter (2). 3. Install oil pressure gauge (1). 4. Start engine and record oil pressure. CAUTION: If oil pressure is 0 at idle, do not perform the 3000 RPM test 5. If oil pressure is 0 at idle, shut off engine. check for pressure relief valve stuck open, a clogged oil pick-up screen. 6. Remove oil pan and inspect for debrisSee: Oil Pan/Service and Repair/Engine Oil Pan - Removal. 7. Remove oil pressure relief valveSee: Oil Pump/Oil Pressure Regulator Valve/Service and Repair/Removal and Replacement/Oil Pressure Relief Valve - Removal and inspect, if damaged replace pressure relief valve. 8. If pressure relief valve is ok, replace balance shaft module assemblySee: Oil Pump/Service and Repair/Removal and Replacement/Engine Oil Pump - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure > Page 1797 9. After test is complete, remove test gauge (1) and fitting (2). 10. Install oil pressure sensor and electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1802 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil and Oil Filter ....................................................................................................................... .......................................................... 4.26L (4.5 Qt) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1805 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ............................................................... SAE 5W-20 Use API certified engine oil. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1806 Engine Oil: Description and Operation ENGINE OIL WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your government agency for location of collection center in your area. When service is required, Chrysler Corporation recommends that only Mopar(R) brand parts, lubricants and chemicals be used. Mopar (R) provides the best engineered products for servicing Chrysler Corporation vehicles. Only lubricants bearing designations defined by the following organization should be used: - Society of Automotive Engineers (SAE) - American Petroleum Institute (API) - National Lubricating Grease Institute (NLGI) - Association des Constructeurs Europeens d' Automobiles (European Automobile Manufacturers Association) (ACEA) API CERTIFICATION AND LICENSE SYMBOL Use an engine oil that is API Certified and Licensed to display the certification mark. Mopar (R) provides engine oils that meet or exceed, Material Standard MS-6395 requirement. SAE VISCOSITY Refer to the engine oil filler cap for the preferred engine oil viscosity grade for each vehicle. SAE viscosity grades are used to specify the correct viscosity oil for an engine. Use only Multi-Viscosity oils. These are specified with a dual SAE viscosity grade which indicates the cold (5W) to hot (20) temperature performance range of the oil. CONTAINER IDENTIFICATION The Engine Oil Certification Mark was developed and trademarked by the API to refer customers to those engine oils preferred by the automobile manufacturers. This symbol means that the oil has been certified and licensed by the American Petroleum Institute (API). This certification mark will Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1807 only be found on the front of the oil containers. Those oils that do not display the "Mark" on the front of the container should not be used. Chrysler only recommends API Certified engine oils that meet the requirements of Material Standard MS-6395. Use Mopar or an equivalent oil meeting the specification MS-6395. SYNTHETIC ENGINE OILS There are a number of engine oils being promoted as either synthetic or semi-synthetic. If you choose to use such a product, use only those oils that are certified by the American Petroleum Institute (API) to display the "Certification Mark" and show SAE viscosity grade recommended for each vehicle. Follow the service schedule that describes your driving type. ENGINE OIL ADDITIVES/SUPPLEMENTS The manufacturer does not recommend the addition of any engine oil additives/supplements to the specified engine oil. Engine oil additives/supplements should not be used to enhance engine oil performance. Engine oil additives/supplements should not be used to extend engine oil change intervals. No additive is known to be safe for engine durability and can degrade emission components. Additives can contain undesirable materials that harm the long term durability of engines and emission systems by: - Increasing the level of Phosphorus and Sulfur in the engine oil. The API Certified Engine Oils control the Phosphorus and Sulfur contents of the oil to levels that reduce the contamination effect on the vehicle's emission control system. - Altering the viscosity characteristics of the engine oil so that it no longer meets the requirements of the specified viscosity grade. - Creating potential for an undesirable additive compatibility interaction in the engine crankcase. The engine oils contain a performance additive system carefully developed to optimize the oil's performance in the engine. The addition of supplements may cause the oil to thicken prematurely, cause excessive deposit build-up and potentially shorten engine life. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check Engine Oil: Service and Repair Engine Oil Level Check ENGINE OIL LEVEL CHECK NOTE: The engine must be HOT when checking oil level. The best time to check engine oil level is after the engine is at operating temperature. Allow the engine to be shut off for at least 5 minutes before checking oil level. Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove dipstick (1), and observe oil level. Add oil only when the level is at or below the SAFE mark. If the oil level is in the safe (2) range, do not add oil. CAUTION: Do not operate engine if the oil level is above the MAX mark on the dipstick. Excessive oil volume can cause oil aeration which can lead to engine failure due to loss of oil pressure or increase in oil temperature. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check > Page 1810 Engine Oil: Service and Repair Engine Oil and Filter Change ENGINE OIL AND FILTER CHANGE WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. Change engine oil at mileage and time intervals described in the Maintenance Schedule See: Maintenance. 1. Run engine until achieving normal operating temperature. 2. Position the vehicle on a level surface and turn engine off. 3. Remove oil fill cap. 4. Raise vehicle on hoist. 5. Place a suitable oil collecting container under oil pan drain plug (2). 6. Remove oil pan drain plug (2) or and allow oil to drain into collecting container. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 7. Remove oil filter (1) See: Oil Filter/Service and Repair/Removal and Replacement/Engine Oil Filter - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check > Page 1811 8. Install oil pan drain plug (2) and tighten drain plug to 28 Nm (20 ft. lbs.). 9. Install new oil filter (1)See: Oil Filter/Service and Repair/Removal and Replacement/Engine Oil Filter - Installation. 10. Lower vehicle and fill crankcase with specified type and amount of engine oil and . 11. Install oil fill cap. 12. Start engine and inspect for leaks. 13. Stop engine and inspect oil level. OIL FILTER SPECIFICATION All engines are equipped with a high quality full-flow, disposable type oil filter. Replace oil filter with a Mopar(R) or the equivalent. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING listed above. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Description and Operation Oil Cooler: Description and Operation DESCRIPTION An engine oil cooler is used on some engine packages. The cooler is a coolant-to-oil type and mounted between the oil filter and oil filter adapter. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler - Removal Oil Cooler: Service and Repair Engine Oil Cooler - Removal REMOVAL NOTE: The oil cooler can not be cleaned out. In the event that the engine requires rebuilding or replacement, the oil cooler should be replaced. 1. Raise vehicle on hoist. 2. Drain cooling system See: Cooling System/Service and Repair. 3. Disconnect oil cooler coolant hoses. 4. Remove oil filter (3). 5. Remove oil cooler connector bolt (2). 6. Remove oil cooler (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler - Removal > Page 1817 Oil Cooler: Service and Repair Engine Oil Cooler - Installation INSTALLATION 1. Replace oil cooler seal (1). 2. Lubricate seal and position oil cooler to oil filter adapter, aligning notch to tab. 3. Install oil cooler connector bolt (2). Tighten connector bolt to 55 Nm (41 ft. lbs.). 4. Install oil filter (3). 5. Connect oil cooler coolant hose. 6. Lower vehicle. 7. Fill cooling system See: Cooling System/Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Procedures Oil Filter: Procedures ENGINE OIL AND FILTER CHANGE WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. Change engine oil at mileage and time intervals described in the Maintenance Schedule See: Maintenance. 1. Run engine until achieving normal operating temperature. 2. Position the vehicle on a level surface and turn engine off. 3. Remove oil fill cap. 4. Raise vehicle on hoist. 5. Place a suitable oil collecting container under oil pan drain plug (2). 6. Remove oil pan drain plug (2) or and allow oil to drain into collecting container. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 7. Remove oil filter (1) See: Removal and Replacement/Engine Oil Filter - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Procedures > Page 1822 8. Install oil pan drain plug (2) and tighten drain plug to 28 Nm (20 ft. lbs.). 9. Install new oil filter (1)See: Removal and Replacement/Engine Oil Filter - Installation. 10. Lower vehicle and fill crankcase with specified type and amount of engine oil and . 11. Install oil fill cap. 12. Start engine and inspect for leaks. 13. Stop engine and inspect oil level. OIL FILTER SPECIFICATION All engines are equipped with a high quality full-flow, disposable type oil filter. Replace oil filter with a Mopar(R) or the equivalent. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING listed above. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Procedures > Page 1823 Oil Filter: Removal and Replacement Engine Oil Filter - Removal REMOVAL CAUTION: When servicing the oil filter, avoid deforming the filter can by installing the remove/install tool band strap against the can to base lock seam. The lock seam joining the can to the base is reinforced by the base plate. 1. Using a suitable filter wrench, turn oil filter (1) counterclockwise to remove. Engine Oil Filter - Installation INSTALLATION 1. Clean and check filter mounting surface. The surface must be smooth, flat and free of debris or pieces of gasket. 2. Lubricate new oil filter gasket. 3. Screw oil filter (1) on until the gasket contacts base. Tighten to 14 Nm (11 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications OIL PAN Oil Pan-Bolts M6 Bolts.......................................................................................................................... .............................................................................9 Nm (80 in. lbs.) M8 Bolts...................................... .............................................................................................................................................................. ..24 Nm (18 ft. lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Oil Pan - Removal Oil Pan: Service and Repair Engine Oil Pan - Removal REMOVAL 1. Raise vehicle on hoist. 2. Remove oil drain plug (2) and drain the engine oil. 3. Remove accessory drive belt splash shield. 4. Remove lower A/C compressor mounting bolt (if equipped). 5. Remove A/C mounting bracket (2). NOTE: Do not use pry points in block to remove oil pan. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Oil Pan - Removal > Page 1829 6. Remove oil pan retaining bolts. 7. Using a putty knife (1), loosen seal around oil pan (2). 8. Remove oil pan (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Oil Pan - Removal > Page 1830 Oil Pan: Service and Repair Engine Oil Pan - Installation INSTALLATION NOTE: Oil pan sealing surfaces must be free of grease or oil. NOTE: Parts must be assembled within 10 minutes of applying RTV. 1. Apply Mopar(R) Engine RTV GEN II at the front cover to engine block parting lines (1). 2. Apply a 2 mm bead of Mopar(R) Engine RTV GEN II around the oil pan as shown. 3. Position oil pan and install bolts. Tighten bolts to 12 Nm (105 in. lbs.). NOTE: The 2 long bolts must be tightened to 22 Nm (195 in.lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Oil Pan - Removal > Page 1831 4. Install oil drain plug (2). 5. Lower vehicle and fill engine crankcase with proper oil to correct level. 6. Start engine and check for leaks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1835 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1836 Oil Pressure Sender: Diagrams Connector - (POWERTRAIN) 2 WAY SWITCH-ENGINE OIL PRESSURE - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Description and Operation > Oil Pressure Switch - Description Oil Pressure Switch (For Fuel Pump): Description and Operation Oil Pressure Switch - Description DESCRIPTION The oil pressure switch is located on the left front side of the engine block. The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Description and Operation > Oil Pressure Switch - Description > Page 1841 Oil Pressure Switch (For Fuel Pump): Description and Operation Oil Pressure Switch - Operation OPERATION The oil pressure switch is normally "Closed." The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig. The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Raise and support the vehicle See: Maintenance/Vehicle Lifting/Service and Repair 3. Remove the splash shield from the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 4. Remove the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal 5. Remove the three bolts (2) and reposition the A/C compressor (1). 6. Disconnect the oil pressure switch electrical connector. 7. Remove the oil pressure switch using oil pressure socket C-4597 (1) or equivalent. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal > Page 1844 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Installation INSTALLATION NOTE: If the oil pressure switch is removed, it must be replaced with a new switch. CAUTION: The oil pressure switch has tapered threads, over tightening could crack the engine block. 1. Install the oil pressure switch using oil pressure socket C-4597 (1) or equivalent. Tighten switch to 8 Nm (71 in. lbs.). 2. Connect the oil pressure switch electrical connector. 3. Position the A/C compressor (1) and install three mounting bolts (2). Tighten bolts to 25 Nm (18 ft. lbs.). 4. Install the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation 5. Install the splash shield to the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 6. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications ENGINE OIL PRESSURE At Curb Idle Speed*.............................................................................................................................. ....................................................25 kPa (4 psi. min.) At 3000 rpm...................................................... ............................................................................................................................170 - 550 kPa (25 80 psi.) CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure Engine Oil Pressure: Testing and Inspection Checking Engine Oil Pressure CHECKING ENGINE OIL PRESSURE NOTE: Anytime the oil temperature sensor is removed, it should be replaced with a new sensor. 1. Disconnect and remove oil temperature sensor (1). CAUTION: Threads in cylinder head are British Standard Pipe (BSP). Do not install a NPT threaded adapter, this could crack the cylinder head. 2. Install threaded adapter 9879 (1). 3. Install oil pressure gauge (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure > Page 1851 4. Start engine and record reading on oil pressure gauge (1). CAUTION: If oil pressure is 0 at idle, do not perform the 3000 RPM test 5. If oil pressure is 0 at idle, shut off engine. Check for pressure relief valve stuck open, a clogged oil pick-up screen. 6. Remove oil pan and inspect for debrisSee: Oil Pan/Service and Repair/Engine Oil Pan - Removal. 7. Remove oil pressure relief valveSee: Oil Pressure Regulator Valve/Service and Repair/Removal and Replacement/Oil Pressure Relief Valve Removal. and 8. Inspect oil pressure relief valveSee: Oil Pressure Regulator Valve/Service and Repair/Procedures if damaged replace. 9. If pressure relief valve is ok, replace balance shaft module assemblySee: Service and Repair/Removal and Replacement/Engine Oil Pump Removal. 10. After test is complete, remove oil pressure gauge (2) and adapter 9879 (1). 11. Install a new oil pressure temperature sensor (1) and connect electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure > Page 1852 Engine Oil Pressure: Testing and Inspection Checking VVT Oil Pressure CHECKING VVT OIL PRESSURE This test can be used to help diagnose VVT faults. 1. Disconnect and remove oil pressure sensor (1). CAUTION: Threads in block are 1/8"-28 British Standard Pipe (BSP). Do not install a National Pipe Thread (NPT) threaded adapter, this could crack the cylinder block. 2. Install an 1/8-28 BSP male to 1/8-27 female threaded adapter (2). 3. Install oil pressure gauge (1). 4. Start engine and record oil pressure. CAUTION: If oil pressure is 0 at idle, do not perform the 3000 RPM test 5. If oil pressure is 0 at idle, shut off engine. check for pressure relief valve stuck open, a clogged oil pick-up screen. 6. Remove oil pan and inspect for debrisSee: Oil Pan/Service and Repair/Engine Oil Pan - Removal. 7. Remove oil pressure relief valveSee: Oil Pressure Regulator Valve/Service and Repair/Removal and Replacement/Oil Pressure Relief Valve Removal and inspect, if damaged replace pressure relief valve. 8. If pressure relief valve is ok, replace balance shaft module assemblySee: Service and Repair/Removal and Replacement/Engine Oil Pump Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure > Page 1853 9. After test is complete, remove test gauge (1) and fitting (2). 10. Install oil pressure sensor and electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Service and Repair > Procedures Oil Pressure Regulator Valve: Procedures INSPECTION NOTE: Pressure regulating valve (4) can be service separately from the oil pump assembly. 1. Inspect pressure relief valve (4) scoring, gouging, or debris. Replace as needed. 2. Inspect the pressure relief valve bore in the pump for scoring, gouging, or debris. 3. If pump bore is damaged, replace balance shaft module. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Service and Repair > Procedures > Page 1858 Oil Pressure Regulator Valve: Removal and Replacement Oil Pressure Relief Valve - Removal REMOVAL 1. Remove oil panSee: Oil Pan/Service and Repair/Engine Oil Pan - Removal 2. Remove pressure regulating valve cap (2). 3. Remove pressure regulating valve spring (3) and valve (4). Oil Pressure Relief Valve - Installation INSTALLATION 1. Lightly coat pressure regulating valve with clean engine oil and install valve (4). 2. Install spring (3) and cap (2). 3. Tighten cap to 44 Nm (32 lbs.ft.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Spray Jet > Component Information > Service and Repair > Piston Oil Cooler Jet - Removal Oil Spray Jet: Service and Repair Piston Oil Cooler Jet - Removal REMOVAL 1. Remove engine See: Service and Repair/Removal and Replacement/Engine - Removal and place on a suitable stand. 2. Remove oil drain plug (2) and drain oil. 3. Remove oil panSee: Oil Pan/Service and Repair/Engine Oil Pan - Removal. 4. Remove balance shaft module/oil pumpSee: Oil Pump/Service and Repair/Removal and Replacement/Engine Oil Pump - Removal. 5. Remove ladder frame. 6. Remove oil jet fastener (1). 7. Remove oil jet (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Spray Jet > Component Information > Service and Repair > Piston Oil Cooler Jet - Removal > Page 1863 Oil Spray Jet: Service and Repair Piston Oil Cooler Jet - Installation INSTALLATION 1. Install oil jet (2). 2. Install fastener (1) and tighten to 12 Nm (105 in.lbs.). 3. Install ladder frameSee: Cylinder Block Assembly/Service and Repair/Removal and Replacement/Ladder Frame - Installation. 4. Install oil pan (1)See: Oil Pan/Service and Repair/Engine Oil Pan - Installation. 5. Install engine See: Service and Repair/Removal and Replacement/Engine - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 1867 Oil Temperature Sensor/Switch: Diagrams Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-OIL TEMPERATURE (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Oil Temperature Sensor - Removal Oil Temperature Sensor/Switch: Service and Repair Oil Temperature Sensor - Removal REMOVAL 1. Disconnect oil temperature sensor (1) electrical connector. 2. Remove sensor (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Oil Temperature Sensor - Removal > Page 1870 Oil Temperature Sensor/Switch: Service and Repair Oil Temperature Sensor - Installation INSTALLATION 1. If re-using the oil temperature sensor, coat the threads with Mopar(R) thread sealant. 2. Install oil temperature sensor (1). Tighten to 18 Nm (160 in. lbs.). 3. Connect electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications INTAKE MANIFOLD Intake Manifold-Bolts............................................................................................................................ ......................................................24 Nm (18 ft. lbs.) THROTTLE BODY Tighten the bolts in a mandatory torque criss - cross pattern sequence to................................................................................................7.5 Nm (65 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1874 Intake Manifold: Testing and Inspection INTAKE MANIFOLD LEAKS An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning. WARNING: Use extreme caution when the engine is operating. Do not stand in a direct line with the fan. Do not put your hands near the pulleys, belts or the fan. Do not wear loose clothing. 1. Start the engine. 2. Spray a small stream of water (Spray Bottle) at the suspected leak area. 3. If engine RPM'S change, the area of the suspected leak has been found. 4. Repair as required. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures Intake Manifold: Procedures Intake Manifold - Cleaning CLEANING 1. Discard gasket(s). 2. Clean all sealing surfaces. Intake Manifold - Inspection INSPECTION 1. Inspect manifold for cracks, distortion, or mounting surface warpage. Replace manifold if necessary. 2. Inspect manifold gasket for surface damage or excessive swelling. Replace gaskets as necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 1877 Intake Manifold: Removal and Replacement Intake Manifold - Removal 2.4L WARNING: Release fuel system pressure before servicing system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. 1. Remove engine cover (1). 2. Perform fuel system pressure release procedure before attempting any repairs See: Cylinder Head Assembly/Fuel Pressure Release/Service and Repair. 3. Remove air cleaner inlet (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 1878 4. Remove air cleaner housing (1). 5. Disconnect negative cable at battery (3). 6. Disconnect fuel line at rail (3). 7. Remove fuel injector electrical connectors (4). 8. Remove fuel rail retaining bolts and remove fuel rail. 9. Disconnect oil temperature sensor (1). 10. Disconnect variable valve timing solenoid electrical connector. 11. Disconnect intake camshaft position sensor electrical connector. 12. Position harness out of the way. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 1879 13. Remove throttle body support bracket (1). 14. Disconnect electronic throttle control electrical connector. 15. Remove wiring harness retainer from the intake manifold (2). 16. Disconnect MAP sensor electrical connector. 17. Disconnect vacuum lines at intake. 18. Remove upper radiator hose retaining bracket (1). 19. Remove intake manifold retaining bolts. 20. Remove intake manifold. Intake Manifold - Installation 2.4L Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 1880 1. Clean all gasket surfaces. 2. Replace intake manifold gasket. 3. Install intake manifold, tighten bolts to 25 Nm (220 in. lbs.). 4. Install the fuel rail assembly to intake manifold. Tighten bolts to 23 Nm (200 in. lbs.). 5. Connect fuel injector electrical connectors. 6. Inspect quick connect fittings for damage, replace if necessary See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair. Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position. 7. Connect negative cable to battery (3). 8. Fill the cooling system See: Cooling System/Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 1881 9. Install air cleaner housing (1). 10. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Rear Crankshaft Oil Seal - Removal Crankshaft Main Bearing Seal: Service and Repair Rear Crankshaft Oil Seal - Removal 2.4L 1. Remove transmission and flexplate (1) See: Transmission and Drivetrain/Flex Plate/Service and Repair/Flexplate - Removal. 2. Insert a 3/16 flat bladed screwdriver (7) between the dust lip (8) and the metal case (4) of the crankshaft seal (1). Angle the screwdriver through the dust lip against metal case of the seal. Pry out seal. CAUTION: Do not permit the screwdriver blade to contact crankshaft seal surface. Contact of the screwdriver blade against crankshaft edge (chamfer) is permitted. 3. Check to make sure the seals garter spring is not on the crankshaft. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Rear Crankshaft Oil Seal - Removal > Page 1887 Crankshaft Main Bearing Seal: Service and Repair Rear Crankshaft Oil Seal - Installation 2.4L CAUTION: If a burr or scratch is present on the crankshaft edge (chamfer), cleanup with 800 emery cloth to prevent seal damage during installation of new seal. If emery cloth is used, the crankshaft must be cleaned off Mopar(R) brake parts cleaner. NOTE: When installing seal, lubricate Seal Guide 9509 with clean engine oil. 1. Place Seal Guide 9509 (3) on crankshaft. 2. Position seal (2) over guide tool. Guide tool should remain on crankshaft during installation of seal. Ensure that the lip of the seal is facing towards the crankcase during installation. 3. Drive the seal into the block using Seal Driver 9706 (1) and Driver Handle C-4171 (4) until Seal Driver 9706 bottoms out against the block. 4. Install the flexplate (1) and transmission See: Transmission and Drivetrain/Flex Plate/Service and Repair/Flexplate - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Front Crankshaft Oil Seal - Removal Front Crankshaft Seal: Service and Repair Front Crankshaft Oil Seal - Removal REMOVAL 1. Remove accessory drive belt. 2. Install damper holder 9707 (1) and remove damper retaining bolt. 3. Pull damper off crankshaft. 4. Remove front crankshaft oil seal (1) by prying out with a screw driver (2). Be careful not to damage the cover seal surface. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Front Crankshaft Oil Seal - Removal > Page 1892 Front Crankshaft Seal: Service and Repair Front Crankshaft Oil Seal - Installation INSTALLATION 1. Place seal (1) onto Seal installer 9506 (2) with seal spring towards the inside of engine. 2. Install new seal (1) by using Seal installer 9506 (2) and crankshaft damper bolt (3). 3. Press seal into front cover until Seal Installer 9506 (1) seats against timing chain cover (3). 4. Remove seal installer 9506 (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Front Crankshaft Oil Seal - Removal > Page 1893 5. Install crankshaft vibration damper. 6. Oil the bolt threads and between the bolt head and washer. 7. Install damper retaining bolt and damper holder 9707 (1). Tighten bolt to 50 Nm + 68° (37 ft. lbs. + 68°). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1898 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 1899 Oil Pressure Sender: Diagrams Connector - (POWERTRAIN) 2 WAY SWITCH-ENGINE OIL PRESSURE - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Description and Operation > Oil Pressure Switch - Description Oil Pressure Switch (For Fuel Pump): Description and Operation Oil Pressure Switch - Description DESCRIPTION The oil pressure switch is located on the left front side of the engine block. The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Description and Operation > Oil Pressure Switch - Description > Page 1904 Oil Pressure Switch (For Fuel Pump): Description and Operation Oil Pressure Switch - Operation OPERATION The oil pressure switch is normally "Closed." The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig. The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Raise and support the vehicle See: Maintenance/Vehicle Lifting/Service and Repair 3. Remove the splash shield from the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 4. Remove the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal 5. Remove the three bolts (2) and reposition the A/C compressor (1). 6. Disconnect the oil pressure switch electrical connector. 7. Remove the oil pressure switch using oil pressure socket C-4597 (1) or equivalent. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal > Page 1907 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Installation INSTALLATION NOTE: If the oil pressure switch is removed, it must be replaced with a new switch. CAUTION: The oil pressure switch has tapered threads, over tightening could crack the engine block. 1. Install the oil pressure switch using oil pressure socket C-4597 (1) or equivalent. Tighten switch to 8 Nm (71 in. lbs.). 2. Connect the oil pressure switch electrical connector. 3. Position the A/C compressor (1) and install three mounting bolts (2). Tighten bolts to 25 Nm (18 ft. lbs.). 4. Install the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation 5. Install the splash shield to the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 6. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 1911 Oil Temperature Sensor/Switch: Diagrams Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-OIL TEMPERATURE (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Oil Temperature Sensor - Removal Oil Temperature Sensor/Switch: Service and Repair Oil Temperature Sensor - Removal REMOVAL 1. Disconnect oil temperature sensor (1) electrical connector. 2. Remove sensor (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Oil Temperature Sensor - Removal > Page 1914 Oil Temperature Sensor/Switch: Service and Repair Oil Temperature Sensor - Installation INSTALLATION 1. If re-using the oil temperature sensor, coat the threads with Mopar(R) thread sealant. 2. Install oil temperature sensor (1). Tighten to 18 Nm (160 in. lbs.). 3. Connect electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Gear/Sprocket Variable Valve Timing Phaser ............................................................................................................. ..................................................... 59 Nm (44 ft. lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Description and Operation > Variable Valve Timing Assembly - Description Camshaft Gear/Sprocket: Description and Operation Variable Valve Timing Assembly - Description DESCRIPTION The world engine is equipped with Variable Valve Timing (VVT). This system advances and/or retards intake and/or exhaust camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy, and reduce emissions. The camshaft sprockets are integrated with the VVT assemblies and are serviced as an assembly. VVT assemblies are sometimes referred to as camshaft phasers. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Description and Operation > Variable Valve Timing Assembly - Description > Page 1921 Camshaft Gear/Sprocket: Description and Operation Variable Valve Timing Assembly - Operation OPERATION The Variable Valve Timing (VVT) assemblies are actuated with engine oil pressure. The oil flow to the VVT assemblies are controlled by two Oil Control Valves (OCV). There is an OCV and Camshaft Position Sensor (CMP) for each camshaft. The OCV's consist of a Pulse Width Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through the spool valve into the VVT assemblies. The VVT assembly consists of a rotor, stator, and sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected to the camshaft. Oil flow in to the VVT assembly rotates the rotor with respect to the stator, thus rotating the camshaft with respect to the timing chain. Thus, the VVT assemblies change valve timing by changing the relationship between the camshaft and the timing chain. An infinitely variable valve timing position can be achieved within the limits of the hardware. The CMP monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Variable Valve Timing Assembly - Removal Camshaft Gear/Sprocket: Service and Repair Variable Valve Timing Assembly - Removal REMOVAL NOTE: Camshaft phaser and camshaft sprocket are supplied as an assembly, do not attempt to disassemble. 1. Remove camshaftsSee: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Removal. 2. Remove camshaft phaser (2) retaining bolt while holding the camshaft in place with a wrench (1) on the camshaft flats. 3. Remove phaser (2) assembly from camshaft. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Variable Valve Timing Assembly - Removal > Page 1924 Camshaft Gear/Sprocket: Service and Repair Variable Valve Timing Assembly - Installation INSTALLATION CAUTION: Do not use an impact wrench to tighten camshaft sprocket bolts. Damage to the camshaft-to-sprocket locating dowel pin and camshaft phaser may occur. 1. Install phaser (2) assembly on camshaft. NOTE: Make sure the dowel is seated in the dowel hole and not in a oil feed hole. The dowel hole is larger than the 4 oil feed holes. 2. Install phaser retaining bolt. Hold camshaft in place with a wrench (1) and tighten bolt to 59 Nm (44 ft. lbs.). 3. Install camshaftsSee: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Description and Operation Timing Chain: Description and Operation DESCRIPTION The crankshaft sprocket on the SRT4 engine has friction washers attached to both sides of the sprocket. The washers have four clips that attach them to the sprocket. The washers are designed to remain on the sprocket during disassembly and assembly. The friction washers are serviced as an assembly with the sprocket. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures Timing Chain: Procedures INSPECTION Inspect timing chain for stretching prior to removal. 1. Rotate engine while watching timing chain tensioner plunger. When the plunger reaches its maximum travel stop rotating engine. 2. Measure the distance from the tensioner body and the edge of the chain guide as shown. 3. If the distance is greater than 20.5 mm (0.81 in.) inspect guide shoes for excessive wear. 4. If guides are okay, replace timing chain. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 1930 Timing Chain: Removal and Replacement Timing Chain TIMING CHAIN 1. Set engine to TDC. 2. Remove timing chain coverSee: Timing Cover/Service and Repair/Engine Timing Cover(s) - Removal. NOTE: If the timing chain plated links can no longer be seen, the timing chain links corresponding to the timing marks must be marked prior to removal if the chain is to be reused. 3. Mark chain link (1) corresponding to camshaft timing mark. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 1931 4. Mark chain link (3) corresponding to crankshaft timing mark (2). 5. Remove timing chain tensioner (5) See: Timing Chain Tensioner/Service and Repair/Engine Timing Tensioner - Removal 6. Remove timing chain (2). Camshaft Sprocket(s) CAMSHAFT SPROCKET(S) NOTE: Camshaft phasers and camshaft sprockets are supplied as an assembly, do not attempt to disassemble. Refer to camshaft phaser removalSee: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Removal. Crankshaft Sprocket CRANKSHAFT SPROCKET Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 1932 1. Remove timing chainSee: Timing Chain & Sprockets - Removal. 2. Remove oil pan See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Removal. 3. Remove oil pump drive chain tensioner. 4. Remove oil pump drive chain. 5. Remove crankshaft sprocket (1). Timing Chain TIMING CHAIN NOTE: The crankshaft timing mark (3) or (5) can be in one of two locations depending on whether the engine is early production (5), late production (3) or assembled with service parts (3). In all cases the keyway (2) will always be in the 9:00 position, in line with the ladder frame mounting surface (1) when the engine is at TDC. 1. Verify that the engine is still set to TDC. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 1933 2. Align camshaft timing marks (3) so they are facing each other and in line with the cylinder head cover sealing surface (2). 3. Install timing chain so plated (or marked) links on chain align with timing marks on camshaft sprockets (1). 4. Align timing mark on the crankshaft sprocket (3) or (5) with the plated (or marked) link (4) on the timing chain. Position chain so slack will be on the tensioner side. NOTE: Keep the slack in the timing chain on the tensioner side. 5. Install the timing chain tensioner (5) See: Timing Chain Tensioner/Service and Repair/Engine Timing Tensioner - Installation Rotate the crankshaft CLOCKWISE two complete revolutions until the crankshaft is repositioned at the TDC position with the key way at the 9 o'clock position. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 1934 6. Verify that the camshafts timing marks (3) are in the proper position and in line with the cylinder head cover sealing surface. If the marks do not line up, the timing chain is not correctly installed. 7. Install front timing chain coverSee: Timing Cover/Service and Repair/Engine Timing Cover(s) Installation. 8. Connect negative battery cable. 9. Operate engine until it reaches normal operating temperature. Check oil and cooling systems for correct fluid levels. Crankshaft Sprocket CRANKSHAFT SPROCKET 1. Install crankshaft sprocket (1) onto crankshaft. 2. Install oil pump drive chain. Verify that Oil pump is correctly timed (1,2,5,6). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 1935 3. Reset oil pump drive chain tensioner by pushing plunger inward and install tensioner pin 8514. 4. Install oil pump drive chain tensioner (3) and remove Tensioner Pin 8514 (4). 5. Install timing chain See: Timing Chain & Sprockets - Installation. 6. Install oil panSee: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Installation. 7. Fill engine with oilSee: Engine Lubrication/Engine Oil/Service and Repair. 8. Start engine and check for leaks. Camshaft Sprocket(s) CAMSHAFT SPROCKET(S) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Procedures > Page 1936 NOTE: The camshaft sprockets and the camshaft phasers are an assembly and cannot be serviced separately. CAUTION: Do not use an impact wrench to tighten camshaft sprocket bolts. Damage to the camshaft-to-sprocket locating dowel pin and camshaft phaser may occur. 1. Refer to Camshaft phaser (2) installationSee: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications TIMING CHAIN TENSIONER Timing Chain Tensioner Assembly-Bolts.............................................................................................. ...................................................12 Nm (106 in. lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Engine Timing Tensioner - Removal Timing Chain Tensioner: Service and Repair Engine Timing Tensioner - Removal REMOVAL 1. Remove the engine timing cover See: Timing Cover/Service and Repair/Engine Timing Cover(s) - Removal. NOTE: Tensioner will not come apart during removal. 2. Remove timing chain tensioner retaining bolts and remove tensioner (5). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Engine Timing Tensioner - Removal > Page 1942 Timing Chain Tensioner: Service and Repair Engine Timing Tensioner - Installation INSTALLATION 1. Reset timing chain tensioner (4) by lifting up on ratchet (2) and pushing plunger (3) inward towards the tensioner body (4). Insert Tensioner Pin 8514 into slot (1) to hold tensioner plunger in the retracted position. NOTE: Keep the slack in the timing chain on the tensioner side. 2. Install timing chain tensioner (1) and tighten bolts to 12 Nm (105 in. lbs.). 3. Remove timing Tensioner Pin 8514 (2). 4. Install the engine timing cover See: Timing Cover/Service and Repair/Engine Timing Cover(s) - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications TIMING COVER Timing Chain Cover M6 Bolts............................................................................................................... ........................................................................................9 Nm (80 in. lbs.) M8 Bolts........................... .............................................................................................................................................................. .............26 Nm (19 ft. lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal Timing Cover: Service and Repair Engine Timing Cover(s) - Removal REMOVAL 1. Remove engine cover (1) by pulling upward. 2. Perform fuel pressure bleed procedureSee: Cylinder Head Assembly/Fuel Pressure Release/Service and Repair. 3. Disconnect and isolate the negative battery cable. 4. Remove coolant recovery bottle (3) See: Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Removal. 5. Remove and reposition power steering reservoir (2). 6. Remove windshield washer bottle (1) See: Wiper and Washer Systems/Windshield Washer Reservoir/Service and Repair/Windshield Washer Reservoir - Removal. 7. Remove accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 1948 8. Remove power steering hose hold down (2). 9. Remove the three power steering pump mounting bolts (1) through the openings in the pulley (3) and reposition the pump. 10. Remove the cylinder head cover See: Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal. 11. Remove ignition coils from cylinder head cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 1949 12. Raise and support the vehicle See: Maintenance/Vehicle Lifting/Service and Repair. 13. Remove the right lower splash shield See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 14. Set engine to TDC (1). 15. Remove lower A/C compressor bolts if equipped. 16. Remove lower A/C compressor mount (2) if equipped. 17. Remove accessory drive belt lower idler pulley (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 1950 18. Remove crankshaft damper (2) See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Vibration Damper Removal. 19. Remove three bolts and water pump pulley (4) from water pump. 20. Remove lower bolt from right side engine mount bracket (1). 21. Remove timing chain cover lower bolts (1). 22. Lower vehicle. 23. Support engine with suitable jack. 24. Remove right engine mount through bolt (4). 25. Remove right engine mount to mount bracket bolts (3). 26. Remove right engine mount adapter (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 1951 27. Remove accessory drive upper idler pulley (1). 28. Remove right upper engine mount bracket (1). 29. Remove accessory drive belt tensioner. 30. Remove timing chain cover retaining bolts. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 1952 31. Remove timing chain cover using pry points (1,2,3). 32. Remove timing chain cover (1) out through the bottom of the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 1953 Timing Cover: Service and Repair Engine Timing Cover(s) - Installation INSTALLATION NOTE: When using RTV, the sealing surfaces must be clean and free from grease and oil. NOTE: When using RTV, parts should be assembled in 10 minutes and tighten to final torque within 45 minutes. 1. Clean all sealing surfaces See: Service and Repair/Procedures/Engine Gasket Surface Preparation. 2. Apply Mopar(R) engine sealant RTV (or equivalent) as shown at the cylinder head to block parting line (1,2). 3. Apply Mopar(R) engine sealant RTV (or equivalent) as shown at the ladder frame to block parting line (1,2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 1954 4. Apply Mopar(R) engine sealant RTV (or equivalent) as shown in the corner of the oil pan and block. 5. Apply 2 mm bead of Mopar(R) engine sealant RTV (or equivalent) to the oil pan as shown. 6. Apply 2 mm bead of Mopar(R) engine sealant RTV (or equivalent) to the engine block (1,2) as shown. 7. Install timing chain cover (1) upwards from under the vehicle. 8. Install timing chain cover upper retaining bolts and tighten M6 bolts to 9 Nm (80 in. lbs.) and M8 bolts to 26 Nm (230 in. lbs.). 9. Install accessory drive belt tensioner. Tighten bolt to 24 Nm (212 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 1955 10. Install right engine mount bracket (1). Tighten bolts to 50 Nm (37 ft. lbs.). 11. Install accessory drive belt upper idler pulley (1). Tighten bolt to 48 Nm (35 ft. lbs.). 12. Install engine mount adapter (2) and tighten bolts (3) to 68 Nm (50 ft. lbs.). 13. Install engine mount through bolt (4) and tighten to 88 Nm (65 ft. lbs.). 14. Remove jack from under engine. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 1956 15. Raise and support the vehicle See: Maintenance/Vehicle Lifting/Service and Repair. 16. Install oil pan to timing chain cover lower retaining bolts (1) and tighten M6 bolts to 9 Nm (80 in. lbs.). 17. Install water pump pulley (4) and tighten three bolts to 9 Nm (80 in. lbs.). 18. Install crankshaft damper (2) See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Vibration Damper Installation 19. Install accessory drive belt lower idler pulley (2). Tighten bolt to 48 Nm (35 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 1957 20. Install lower A/C compressor mounting bracket (2). Tighten the bolts to 24 Nm (18 ft. lbs.). 21. Install A/C compressor (1). Tighten the bolts to 25 Nm (18 ft. lbs.). 22. Install right lower splash shield See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 23. Lower vehicle. 24. Install cylinder head cover and ignition coils See: Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Installation. 25. Place the power steering pump in mounting position. Install the three bolts (1) through openings in the pulley (3). Tighten the mounting bolts (1) to 26 Nm (19 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 1958 26. Install the power steering hose hold down (2). 27. Install accessory drive beltSee: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation. 28. Install power steering pump reservoir (2). Tighten mounting screw to 12 Nm (106 in. lbs.). 29. Install windshield washer reservoir (1). 30. Install coolant recovery reservoir (3). Tighten mounting bolts to 4 Nm (35 in. lbs.). 31. Install clean air hose (5) and air cleaner housing (1) See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation. 32. Install air cleaner housing inlet. 33. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 1959 34. Operate engine until it reaches normal operating temperature. Check oil system for leaks and correct fluid level. 35. Install engine cover (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > Camshaft Position Solenoid 1/1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > Camshaft Position Solenoid 1/1 > Page 1965 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Diagrams > Camshaft Position Solenoid 1/1 (Powertrain) 2 Way Variable Valve Timing Solenoid: Diagrams Camshaft Position Solenoid 1/1 (Powertrain) 2 Way Connector - (POWERTRAIN) 2 WAY SOLENOID-CAMSHAFT 1/1 POSITION - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Diagrams > Camshaft Position Solenoid 1/1 (Powertrain) 2 Way > Page 1968 Variable Valve Timing Solenoid: Diagrams Camshaft Position Solenoid 1/2 (Powertrain) 2 Way Connector - (POWERTRAIN) 2 WAY SOLENOID-CAMSHAFT 1/2 POSITION - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Valve Timing Solenoid Description Variable Valve Timing Solenoid: Description and Operation Variable Valve Timing Solenoid Description DESCRIPTION Variable valve timing solenoid assembly. The solenoid receives pulse width modulation signal and the current is controlled within 0 ma to 1000 ma. The spool position is controllable at any position to control supply of oil between the advance and retard ports. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Valve Timing Solenoid Description > Page 1971 Variable Valve Timing Solenoid: Description and Operation Variable Valve Timing Solenoid Operation OPERATION There is both an Intake and an exhaust camshaft sensor on vehicles equipped with a World Engine. The variable valve timing system used on World Engines requires the exact position of both the intake and exhaust camshaft. The GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of the camshafts. Intake and exhaust phaser oil control valves are required on World Engine vehicles using variable valve timing. The oil valves direct oil to the Intake and exhaust phasers. Oil pressure in the phasers moves the camshafts to an advanced or retarded position. To resolve this inherent conflict between optimum high and low speed valve timing, the GPEC1 controlled engine uses a variable valve timing system. The variable valve timing system advances and retards valve timing by rotating the position of both the intake and exhaust camshafts. With this system, the intake valve opening can range from 80 to 120 crankshaft degrees after Top Dead Center. Likewise, the exhaust valve opening can range from 85 to 120 crankshaft degrees before Top Dead Center. This degree of flexibility provides many benefits, including: Improved Engine Performance, Increased Fuel Economy, Improved Idle Stability and Decreased Engine Emissions. In non operating condition, the camshaft stays in lockpin position of cam phases. This is 120 degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust camshaft. The variable valve timing system is electronically controlled and hydraulically operated. The GPEC1 receives information from many sensors to determine the optimum valve timing. It then pulse-width modulates oil control valves which direct oil to the cam phasers. The cam phasers use oil pressure to rotate the intake and exhaust camshafts. The rotation of the camshafts is referred to as cam phasing. Before the GPEC1 can begin commanding the camshaft phasing, several enabling conditions must be met: - The engine oil temperature must be at least -6.6°C (20°F) - The oil control valve coil temperature must be less than 140°C (284°F) - Engine speed must be at least 600 to 1000 rpm to achieve minimum oil pressure. - Battery voltage must be at least 10 volts - And there must be no camshaft or crankshaft sensor faults, engine timing faults, or oil control valve faults First we will examine variable valve timing enabling conditions, and then we will take a closer look at the inputs and outputs of the system: - Accelerator pedal position sensor - Oil temperature sensor - Map sensor - Intake cam sensor - Exhaust cam sensor - Crankshaft sensor - GPEC1 - Exhaust phaser oil control valve - Intake phaser oil control valve - Inputs - Engine control module - Outputs - Sensed battery voltage A minimum oil temperature is required to enable variable valve timing operation. Oil temperature and viscosity also have an impact on the operation of variable valve timing after start-up. Oil is used to control the movement of the camshafts. An incorrect oil viscosity could adversely affect the operation of the system or even render the system inoperative. It may even set a fault code. The accelerator pedal position sensor indicates how far the driver wants to open the throttle plate. The GPEC1 calculates an initial camshaft set point based on whether the accelerator pedal is at part throttle or wide open throttle. The MAP sensor provides information regarding engine load. Sensed battery voltage provides information regarding current system voltage. Sensed battery voltage must be at least 10 volts in order for the oil control valves to function properly. This information allows the GPEC1 to adjust camshaft timing to achieve the best fuel economy, the best engine performance or a combination of both. The hall-effect crankshaft sensor provides RPM information and determines when the number one piston is approaching Top Dead Center. The sensor generates a signal as the tone wheel, attached to the crankshaft, rotates. The tone wheel has 60 teeth minus two. When the gap, created by the missing teeth passes by the sensor, a signal is produced that indicates the number one piston is at Top Dead Center. The GPEC1 uses crankshaft sensor data along with camshaft data to determine the actual position of the camshaft. There are two hall-effect camshaft sensors on engines equipped with variable valve timing. The GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of the camshaft. The GPEC1 individually controls each valve. It sends a pulse width modulated signal to move a spool within the outer casing of the valve. Depending upon spool movement, oil is directed through the passages to advance or retard cam timing. The oil control valve also has a special cleaning strategy at Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Valve Timing Solenoid Description > Page 1972 key-on. The cleaning strategy is known as "debris crush mode". At key-on the GPEC1 cycles the oil control valve on and off several (5) times to crush any debris in the oil control valve and prevent the spool valve from sticking. In non operating condition, the camshaft stays in lockpin position of cam phases. This is 120 degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust camshaft. There are two oil control valves. One valve directs oil to the intake cam phaser, the other valve directs oil to the exhaust cam phaser. The valves are designed and function in the same manner. The outer casing of each oil valve has five oil passages. A passage for pressurized supply oil. A passage to the advance chamber of the cam phaser. A passage to the retard chamber of the cam phaser. A passage for oil return from the advance chamber of the cam phaser. A passage for oil return from the retard chamber of the cam phaser. Oil flows through the passages and applies pressure to the cam phasers to change cam timing. There are two cam phasers. One phaser controls the position of the intake camshaft. The other phaser controls the position of the exhaust camshaft. The phasers consist of a sprocket, a rotor vane, and a housing or stator. The exhaust cam phaser also consists of a front bushing and spring. We will discuss the purpose and function of the bushing and spring later. The housing is bolted and permanently fixed to the camshaft sprocket, while the rotor vane is bolted and permanently fixed to the camshaft. With this design, any movement of the rotor vane in relation to the housing will also move the camshaft. The phaser and sprocket are serviced as an assembly. Camshaft and crankshaft sensors provide feedback to the GPEC1 regarding the actual position of the camshafts. The GPEC1 then compares the actual camshaft positioning with desired positioning. If the desired positioning is not achieved within a specified time, during the second key cycle a trouble code is set. There are six new diagnostic trouble codes available to help you determine if the control circuit from the GPEC1 to the oil control valve is intact and operating properly. The codes identify whether the control circuit is open, shorted to ground, or shorted to power. Three trouble codes are related to intake camshaft positioning, the other three codes are specific to exhaust camshaft positioning. The oil control valve contains both electrical and mechanical components. It is electrically controlled by the GPEC1. The electrical current that energizes the coil results in mechanical motion of the spool valve. It is possible to verify both the electrical and mechanical operation of the valve. The oil control valve consists of a coil that is energized to move a spool within an outer casing. The condition of the coil can be tested with a Digital Volt Ohmmeter or DVOM. With the DVOM set to measure resistance, check the coil for an open, a short to ground, or excessive resistance. The correct resistance value of the coil is between 6 and 8 ohms. The mechanical operation of the oil control valve can be tested using actuator commands on the scan tool. Remove the oil control valve, then navigate to the actuator menu and select the oil control valve. Use commands to activate the valve and watch as the spool valve moves back and forth inside the casing. Because the cam phasers are hydraulically operated by engine oil, the condition of the oil is very important. The oil must be of the correct viscosity, not obstructed by debris, to maintain correct pressure. Maintaining the correct oil viscosity is critical to the operation of the variable valve timing system. The wrong oil viscosity may cause the variable valve timing to malfunction and trouble codes to set. The correct oil viscosity for this system is 5W20. Oil must be clean, unobstructed and free to flow through the variable valve timing system. Oil could become obstructed in oil passages located in the cylinder head, cylinder block, or even in the oil screen. In the event oil flow is obstructed, further diagnosis or disassembly may be required to pin point the source of the obstruction. The variable valve timing system relies on oil pressure to advance or retard the position of the camshaft. Insufficient oil pressure will adversely affect the operation of variable valve timing. The minimum oil pressure for this system is 15 psi at normal operating temperature. Though not directly used to change camshaft positioning, the oil screen is an important component of the variable valve timing system. It helps to remove debris going to the variable valve timing components. The oil screen is located in the cylinder block, immediately below the cylinder head. Oil must pass through the oil screen before entering the oil control valve. The cylinder head must be removed to service the oil screen. The intention is not to service the oil screen during vehicle life. How the cam phaser works. The cam phaser assembly has eight separate chambers; four advance chambers and four retard chambers. When camshaft advance is requested, oil enters all four advance chambers and exerts force on the rotor vane. Because the rotor vane is bolted to the camshaft, the entire camshaft profile moves along with the rotor vane. At the same time, oil is forced out of the retard chambers. When camshaft retard is requested oil enters the retard chambers to move the camshaft in the opposite direction. There is a lock pin on one side of the rotor vane that fits inside a recessed area in the housing. The lock pin ensures that the default position of the intake cam phaser is 120 crankshaft degrees full retard and the default position of the exhaust cam phaser is 120 crankshaft degrees full advance. When the engine is turned off, rotational force and inertia move the intake camshaft and rotor vane toward the retard position. The exhaust cam phaser includes a spring and bushing to work against the rotational force of the engine, allowing the exhaust cam phaser to lock in the fully advanced position. Under most conditions the cam phasers are returned to lock pin position when the engine is turned off. In the unique condition of an engine stall, which abruptly shuts off the engine, the cam phasers may not return to the lock pin position. In this case, the phasers will return to the lock pin position at the next start-up. Lock pin position is the most ideal cam timing for idle stability. When engine rpm exceeds approximately 600 to 1000 rpm, oil pressure unlocks the pins and variable valve timing resumes. Once enabling conditions are met, the GPEC1 uses input from sensors to calculate optimum valve timing. There are four preprogrammed modes from which the GPEC1 bases initial valve timing. - Starting - Idle or Part throttle - Wide open throttle - Limp-in or Default From each preprogrammed mode, the GPEC1 adjusts valve timing based on operating conditions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Valve Timing Solenoid Description > Page 1973 GPEC1 has calculated optimum intake valve timing of 112 degrees after Top Dead Center and optimum exhaust valve timing of 97 degrees before Top Dead Center. The GPEC1 pulse width modulates the oil control valves to advance or retard the camshaft to their desired location. The spool valve inside the intake oil control valve is energized and moves to allow pressurized oil into the advance chambers of the intake cam phaser. At the same time, the spool valve inside the exhaust oil control valve is energized and moves to allow pressurized oil into the retard chambers of the exhaust cam phaser. Oil enters the advance chambers of the intake phaser and the retard chambers of the exhaust phaser. Oil pressure releases the lock pin from its locked position and pushes against the rotor vane. Both the rotor vanes are moved, advancing the intake camshaft and retarding the exhaust camshaft. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid Removal Variable Valve Timing Solenoid: Service and Repair Variable Valve Timing Solenoid - Removal Front Solenoid 1/1 FRONT SOLENOID 1/1 1. Disconnect negative battery cable. 2. Remove engine cover. 3. Rotate hose clamp out of way. 4. Disconnect oil pressure sensor electrical connector. 5. Remove oil pressure sensor. 6. Disconnect variable valve timing solenoid electrical connector. 7. Remove variable valve timing solenoid mounting bolt. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid Removal > Page 1976 8. Pull solenoid straight out of cylinder head. Rear Solenoid 1/2 REAR SOLENOID 1/2 1. Disconnect negative battery cable. 2. Remove engine cover. 3. Disconnect variable valve timing solenoid electrical connector. 4. Remove variable valve timing solenoid mounting bolt. 5. Pull solenoid straight out of cylinder head. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid Removal > Page 1977 Variable Valve Timing Solenoid: Service and Repair Variable Valve Timing Solenoid - Installation Front Solenoid 1/1 FRONT SOLENOID 1/1 1. Solenoid for front location 1/1. Note mounting tab location is different between front and rear solenoids. 2. Install solenoid into cylinder head. 3. Install mounting bolt and tighten to 12 Nm (9 ft. lbs.). 4. Install oil pressure sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid Removal > Page 1978 5. Connect electrical connector to oil pressure sensor. 6. Connect electrical connector to Variable valve timing solenoid. 7. Connect negative battery cable. 8. Install engine cover. Rear Solenoid 1/2 REAR SOLENOID 1/2 1. Rear variable valve timing solenoid. Note mounting tab location is different between front and rear solenoids. 2. Install solenoid into cylinder head. 3. Install mounting bolt and tighten to 12 Nm (9 ft. lbs.). 4. Connect electrical connector to Variable valve timing solenoid. 5. Connect negative battery cable. 6. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System Fuel Pressure: Testing and Inspection Checking the Fuel Delivery System CHECKING THE FUEL DELIVERY SYSTEM For a complete wiring diagram, refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. CHECKING THE FUEL PUMP OPERATION 1. Turn the ignition on. NOTE: Diagnose and repair any fuel pump control circuit or relay DTCs before continuing with this test. 2. With a scan tool, actuate the fuel pump control to ON (100%). NOTE: It may be necessary to use a mechanics stethoscope in the next step. 3. Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly, without excessive noise. If necessary, compare to a known good vehicle of similar year, make, and model. NOTE: If the pump has excessive noise or grinding, the pump should be replaced. CAUTION: Stop all actuation tests before continuing. Is the fuel pump operating when actuated? Yes - Go To 2 No - Go To 7 2. CHECKING THE FUEL PRESSURE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Install a fuel pressure gauge on the fuel rail. 3. Turn the ignition on. 4. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: Non SRT fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). CAUTION: Stop all actuation tests before continuing. Select the conclusion that best matches the result of the test: Fuel pressure is within the stated specification - Test complete. Fuel pressure is below the stated specification - Go To 3 Fuel pressure is above the stated specification - Replace the fuel filter/pressure regulator. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 3. RESTRICTED FUEL SUPPLY LINE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1985 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. 3. Install special 5/16 fuel line adapter tool #6539 between disconnected fuel line and the fuel pump module. 4. Attach a fuel pressure test gauge to the T fitting on tool #6539. 5. Turn the ignition on. 6. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: Non SRT fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). CAUTION: Stop all actuation tests before proceeding. Is the fuel pressure within specification? Yes - Repair or replace fuel supply line as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 4 4. SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes - Go To 5 No - Go To 6 5. FUEL TANK SIPHON HOSE OR FUEL LINE RESTRICTED OR DAMAGED 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Gain access to the fuel pump module and the fuel tank module. 3. Inspect the fuel line and siphon hose between the fuel pump module and the fuel tank module. Look for disconnected or damaged lines and hoses. 4. Inspect the fuel pressure regulator for damage or a condition that might cause a fuel flow problem. Make sure that it is seated in the module properly. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 6 6. FUEL PUMP INLET STRAINER 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1986 WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Remove the fuel pump module and inspect the fuel inlet strainer for damage or a condition that might cause a fuel flow problem. Were any problems found? Yes - Replace the Fuel Pump Inlet Strainer. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. 7. FUEL PUMP GROUND CIRCUIT OPEN OR HIGH RESISTANCE 1. Turn the ignition off. 2. Disconnect the Fuel Pump Module harness connector. 3. Using a 12-volt test light connected to 12 volts, check the Fuel Pump Motor Ground circuit at the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Repair the Fuel Pump Ground circuit for an open circuit or high resistance. - Perform the PCM Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1987 Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down FUEL PRESSURE LEAK DOWN For a complete wiring diagram, refer to the Wiring Information. See: Diagrams/Electrical Diagrams WARNING: Follow these safety precautions to reduce the risk of fire and serious possible serious or fatal injury when performing this test procedure. Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. Use extreme caution when connecting and disconnecting fuel lines. - Considerable fuel leakage may occur when servicing the fuel system. Wear protective eye wear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair / replace as necessary. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1988 WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from Gas and Diesel Fuel Pressure/Decay Tester 8978. Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly Fuel Inlet Hose 8978-1 (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect the Reservoir Assembly 534960 (4) to the Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 1989 - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 2. Turn the ignition on, wait five seconds, turn the ignition off and then wait 1 minute before proceeding. 3. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT-4 fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the Checking The Fuel Delivery System diagnostic procedure as directed. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System 5. CHECK FUEL DELIVERY SYSTEM FOR LEAK DOWN WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Close the Fuel System Isolation Valve (1) and then wait five minutes before proceeding. 2. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge (1) - Replace the fuel pump module. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Yes - On Fuel Outlet Gauge (2) - Replace the leaking fuel injector(s). - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - If directed here by another test, return to that test. Otherwise, test complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal Air Filter Element: Service and Repair Air Cleaner - Removal REMOVAL 1. Turn lock retainers (5) and remove fresh air inlet (2) from air cleaner housing (1). 2. Disconnect intake air temperature sensor connector (4). 3. Remove air inlet tube (5) from air cleaner housing (1). 4. Unfasten clasps (2) on sides of air cleaner housing cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 1995 5. Pull air cleaner cover (1) aside. 6. Remove filter element (3). 7. If necessary, clean the inside of the air cleaner housing (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 1996 Air Filter Element: Service and Repair Air Cleaner - Installation INSTALLATION 1. Install new filter element. 2. Place cover over air cleaner housing. Snap clasps (2) in place. 3. Install air inlet tube (5). 4. Connect intake air temperature sensor connector (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 1997 5. Install fresh air inlet (2) on air cleaner housing (1) and lock retainers (5). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove lower rear seat cushion. 2. Remove the fuel pump module cover. 3. Disconnect the electrical connector for fuel pump module. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. Turn ignition key to OFF position. 7. Disconnect negative battery cable. 8. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory. The scan tool must be used to erase a DTC. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications FIRING ORDER 1.8, 2.0, 2.4L The firing order is 1-3-4-2. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications Spark Plug: Specifications Spark Plug Specifications SPARK PLUGS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications > Page 2009 Spark Plug: Specifications Torque SPARK PLUG Spark Plugs.......................................................................................................................................... ........................................................27 Nm (20 ft. lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2010 Spark Plug: Application and ID Spark Plug Type................................................................................................................................... ....................................................................ZFR5F-11 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal Spark Plug: Service and Repair Spark Plug - Removal REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the electrical connectors from ignition coils. 3. Remove the ignition coil mounting bolt. 4. Twist the ignition coil then pull straight up. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 2013 5. Remove the spark plug using a quality socket with a rubber or foam insert. 6. Inspect the spark plug condition. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 2014 Spark Plug: Service and Repair Spark Plug - Installation INSTALLATION CAUTION: Handle the spark plugs with care. Do not drop or force the spark plugs into the wells, damage to the electrodes and/or porcelain body may occur. Always start each spark plug by hand in order to avoid cross-threading the spark plug in the cylinder head. Always tighten spark plugs to the specified torque. Too much or not enough torque will cause damage to the cylinder head and/or spark plug and may lead to poor engine performance. 1. Install each spark plug to the cylinder head. Tighten spark plugs to 27 Nm (20 ft. lbs.). 2. Install ignition coil onto spark plug. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 2015 3. Install ignition coil mounting bolt. Tighten to 9 Nm (79.5 in. lbs.). 4. Connect ignition coil electrical connectors. 5. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION CHECK Compression Pressure ............................................................................................................................................................. 1172-1551 kPa (170-225 psi) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2019 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove engine cover. 4. Disconnect coil electrical connectors and remove coils. 5. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators such as fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 6. Disconnect injector electrical connectors. 7. Insert compression gauge adaptor 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer CH7059 with cable adaptors to the DRBIII(R). For Special Tool identification, . See: Tools and Equipment 8. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. 9. Repeat the previous step for all remaining cylinders. 10. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 11. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 12. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Lash Intake.................................................................................................................................................... ..............................0.17 - 0.23 mm (0.006 - 0.009 in.) Exhaust............................................................ ...................................................................................................................0.27 - 0.33 mm (0.010 0.012 in.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2023 Valve Clearance: Adjustments MEASURING VALVE LASH NOTE: The engine must be cold to measure valve lash. 1. Remove engine cover. 2. Remove cylinder head coverSee: Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal. 3. Rotate camshaft so lobes are vertical (1). 4. Check clearance using feeler gauges. 5. Repeat for all tappets and record readings. 6. If clearance was too small, refer to the Clearance too Small procedure. Clearance too Small. 7. If clearance was too large, refer to the Clearance too Large procedure. Clearance too Large. Clearance too Small Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2024 1. Remove camshaftsSee: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Removal. 2. Specification - clearance = change. 3. Decrease tappet thickness by change figure. 4. Install camshafts See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Installation. 5. Verify that valve lash is correct. Clearance too Large 1. Remove camshaftsSee: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Removal. 2. Clearance - specification = change. 3. Increase tappet thickness by change figure. 4. Install camshaftsSee: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Installation. 5. Verify that valve lash is correct. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications WATER PUMP Water Pump - Bolts.............................................................................................................................. ......................................................24 Nm (18 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2028 Water Pump: Description and Operation GAS ENGINE The water pump (3) on the world engine is attached to the water pump adapter on the front of the cylinder block. The water pump is driven by the accessory drive belt. The water pump is connected to the water plenum by the return tube. Turbocharger equipped engines use a smaller diameter water pump pulley then the naturally a separated engine. This allows increased coolant flow without pump cavation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2029 Water Pump: Testing and Inspection WATER PUMP A quick flow test to determine if the water pump is working effectively is to check heater system for proper operation. A defective pump will not provide an adequate flow of heated coolant through the system. WARNING: DO NOT REMOVE THE COOLING SYSTEM PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. Another flow test to help determine water pump operation is as follows: 1. Remove cooling system pressure cap. 2. Remove a small amount of coolant from the system. 3. Start the engine and warm up until thermostat opens. 4. With the thermostat open and coolant level low, visually inspect for coolant flow. If flow is present, the water pump is pumping coolant through the system. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures Water Pump: Procedures Water Pump - Coolant Air Evacuation COOLANT AIR EVACUATION Evacuating or purging air from the cooling system involves the use of a pressurized air operated vacuum generator. The vacuum created allows for a quick and complete coolant refilling while removing any airlocks present in the system components. NOTE: To avoid damage to the cooling system, ensure that no component would be susceptible to damage when a vacuum is drawn on the system. WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASED COOLANT PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE; PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED; PERSONAL INJURY CAN RESULT. WARNING: WEAR APPROPRIATE EYE AND HAND PROTECTION WHEN PERFORMING THIS PROCEDURE. NOTE: The service area where this procedure is performed should have a minimum shop air requirement of 80 PSI (5.5 bar) and should be equipped with an air dryer system. NOTE: For best results, the radiator should be empty. The vehicle's heater control should be set to the heat position (ignition may need to be turned to the on position but do not start the motor). 1. Refer to the Chrysler Pentastar Service Equipment (Chrysler PSE) Coolant Refiller #85-15-0650 or equivalent tool's operating manual for specific assembly steps. 2. Choose an appropriate adapter cone that will fit the vehicle's radiator filler neck or reservoir tank. 3. Attach the adapter cone (2) to the vacuum gauge (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2032 4. Make sure the vacuum generator/venturi ball valve (3) is closed and attach an airline hose (2) (minimum shop air requirement of 80 PSI/5.5 bar) to the vacuum generator/venturi (1). 5. Position the adaptor cone/vacuum gauge assembly into the radiator filler neck or reservoir tank. Ensure that the adapter cone is sealed properly. 6. Connect the vacuum generator/venturi (2) to the positioned adaptor cone/vacuum gauge assembly (1). 7. Open the vacuum generator/venturi ball valve. NOTE: Do not bump or move the assembly as it may result in loss of vacuum. Some radiator overflow hoses may need to be clamped off to obtain vacuum. 8. Let the system run until the vacuum gauge shows a good vacuum through the cooling system. Refer to the tool's operating manual for appropriate pressure readings. NOTE: If a strong vacuum is being created in the system, it is normal to see the radiator hoses to collapse. 9. Close the vacuum generator/venturi ball valve. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2033 10. Disconnect the vacuum generator/venturi and airline from the adaptor cone/vacuum gauge assembly. 11. Wait approximately 20 seconds, if the pressure readings do not move, the system has no leaks. If the pressure readings move, a leak could be present in the system and the cooling system should be checked for leaks and the procedure should be repeated. 12. Place the tool's suction hose into the coolant's container. NOTE: Ensure there is a sufficient amount of coolant, mixed to the required strength/protection level available for use. For best results and to assist the refilling procedure, place the coolant container at the same height as the radiator filler neck. Always draw more coolant than required. If the coolant level is too low, it will pull air into the cooling system which could result in airlocks in the system. 13. Connect the tool's suction hose (1) to the adaptor cone/vacuum gauge assembly (2). 14. Open the suction hose's ball valve to begin refilling the cooling system. 15. When the vacuum gauge reads zero, the system is filled. NOTE: On some remote pressurized tanks, it is recommended to stop filling when the proper level is reached. 16. Close the suction hose's ball valve and remove the suction hose from the adaptor cone/vacuum gauge assembly. 17. Remove the adaptor cone/vacuum gauge assembly from the radiator filler neck or reservoir tank. 18. With heater control unit in the HEAT position, operate engine with container cap in place. 19. After engine has reached normal operating temperature, shut engine off and allow it to cool. When engine is cooling down, coolant will be drawn into the radiator from the pressure container. 20. Add coolant to the recovery bottle/container as necessary. Only add coolant to the container when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion. Add necessary coolant to raise container level to the COLD MINIMUM mark after each cool down period. 21. Once the appropriate coolant level is achieved, attach the radiator cap or reservoir tank cap. Water Pump - Inspection WATER PUMP Replace water pump body assembly if it has any of these defects: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2034 - Cracks or damage on the body. - Coolant leaks from the shaft seal, evident by wet coolant traces on the pump body. - Loose or rough turning bearing. - Impeller rubs either the pump body or the engine block. - Impeller loose or damaged. - Sprocket or sprocket flange loose or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2035 Water Pump: Removal and Replacement Water Pump - Removal GAS ENGINE 1. Remove the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. 2. Raise vehicle See: Maintenance/Vehicle Lifting/Service and Repair. 3. Remove accessory drive belt splash shield. 4. Drain cooling system See: Cooling System/Service and Repair. 5. Remove screws attaching water pump pulley (1). Remove pulley (1). 6. Remove water pump mounting bolts (2). 7. Remove water pump (3). Water Pump - Disassembly WATER PUMP - GAS ENGINE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2036 1. Remove the water pump assembly from the vehicle.See: Water Pump - Removal 2. Discard the water pump outlet gasket (7). 3. Remove the three bolts (1) attaching the water pump pulley (2) to the water pump (4). 4. Remove the water pump pulley (2). 5. Remove the five bolts (3) attaching the water pump (4) to the water pump adapter (6). 6. Remove and discard the gasket (8). 7. Remove the water pump (4) and inspect carefully for any damage. See: Procedures/Water Pump Inspection Water Pump - Assembly WATER PUMP - GAS ENGINE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2037 1. Throughly clean all gasket mating surfaces before assembling. 2. Inspect water pump and components for any damage.See: Procedures/Water Pump - Inspection 3. Using bolts (3), install the water pump (4) and gasket (8) to the water pump adapter (6). Tighten the bolts (3) to 22 N-m (16 lbs. ft.) 4. Using bolts (1), install the water pump pulley (2) to the water pump (4). Tighten the bolts (1) to 9 N-m (80 lbs. in.) 5. Using bolts (5), install the water pump assembly and gasket to the engine block. Tighten the bolts to 24 Nm (18 lbs. ft.).See: Water Pump Installation 6. Start the engine and check for leaks.See: Cooling System/Testing and Inspection Water Pump - Installation GAS ENGINE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2038 1. Position the water pump assembly (1) and gasket onto the cylinder block. 2. Position the water inlet tube (4) and gasket onto the water pump (1). 3. Install the mounting bolts (2). Tighten the bolts to 24 Nm (18 ft. lbs.). 4. Install the drive belt splash shield. 5. Lower the vehicle. 6. Install the accessory drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation. 7. Evacuate air and refill cooling system.See: Procedures/Water Pump - Coolant Air Evacuation 8. Check cooling system for leaks.See: Cooling System/Testing and Inspection Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2044 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Coolant .................................................................................................................................... ............................................... 7.2 Quarts (6.8 Liters) Note: Includes heater and coolant recovery bottled filled to MAX level. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2047 Coolant: Fluid Type Specifications Mopar Antifreeze/Coolant 5 year/100,000 mile formula HOAT (Hybrid Organic Additive Technology) or equivalent. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Description Coolant: Description and Operation Description DESCRIPTION GAS ENGINES WARNING: Antifreeze is an ethylene glycol based coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene glycol. Keep out of reach of children. Dispose of glycol based coolant properly, contact your government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less boiling protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol based coolant with hybrid organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. The green coolant MUST NOT BE MIXED with the orange or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Doing so will reduce the corrosion protection and may result in premature water pump seal failure. If non-HOAT coolant is introduced into the cooling system in an emergency, it should be replaced with the specified coolant as soon as possible. DIESEL ENGINE CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less boiling protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Glysantin G 30-91 Antifreeze/Coolant, 5 Year/150,000 Mile Formula (ASTM D3306), or the equivalent ethylene glycol based coolant. This coolant offers the best engine cooling without corrosion when mixed with 50% coolant and 50% distilled water to obtain a freeze point of -36°C (-34°F). It is dyed purple to distinguish it's unique chemistry from traditional green and yellow silicate coolants. If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. The purple coolant MUST NOT BE MIXED with the orange, green or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant. CAUTION: Glysantin G 30-91 Antifreeze/Coolant, 5 Year/150,00 Mile Formula (ASTM D3306) may not be mixed with any other type of antifreeze. Doing so will reduce the corrosion protection and may result in premature water pump seal failure. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Description > Page 2050 Coolant: Description and Operation Description - HOAT Coolant HOAT COOLANT WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene-glycol. Keep out of reach of children. Dispose of glycol base coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol, but this is not suitable for use in a cooling system. Water also freezes at a higher temperature, boils at a lower temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Description > Page 2051 Coolant: Description and Operation Operation COOLANT Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Page 2052 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -46°C (-50°F). The use of a hydrometer or a refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer Tool 8286 See: Tools and Equipment will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant corrosion protection will be severely reduced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Water Pump Inlet Tube - Removal Coolant Line/Hose: Service and Repair Water Pump Inlet Tube - Removal REMOVAL The water pump inlet tube (2) connects the water pump to the coolant adapter. This tube is sealed by an O-ring and held in place by fasteners to the water pump housing. 1. Drain cooling system See: Service and Repair. 2. Remove the coolant adapter and secondary thermostat See: Thermostat/Service and Repair/Engine Coolant Thermostat - Removal. 3. Raise and support vehicle. 4. Remove inlet tube mounting nuts (1). 5. Remove inlet tube (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Water Pump Inlet Tube - Removal > Page 2057 Coolant Line/Hose: Service and Repair Water Pump Inlet Tube - Installation INSTALLATION 1. Inspect the O-ring for damage before installing the tube. Replace O-ring as necessary. 2. Lubricate O-rings with soapy water. 3. Install new water inlet gasket between tube and water pump housing (2). 4. Position water pump inlet tube (3) on water pump housing (2). Hand tighten nuts to aide in tube alignment. 5. Install secondary thermostat and coolant adapter See: Thermostat/Service and Repair/Engine Coolant Thermostat - Installation. 6. Tighten coolant tube nuts (1) to 24 Nm (212 in. lbs.). 7. Fill cooling system See: Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Description Coolant Reservoir: Description and Operation Description GAS ENGINE The coolant recovery system consists of a coolant recovery container mounted to the RH inner wheel housing, a vent hose for the coolant recovery container, a hose connecting the container to the radiator neck, and a pressure cap. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Description > Page 2062 Coolant Reservoir: Description and Operation Operation GAS ENGINE The system works in conjunction with the cooling system pressure cap to utilize thermal expansion and contraction of the coolant to keep the coolant free of trapped air. The system provides space for expansion and contraction. Also, the system provides a convenient and safe method for checking and adjusting the coolant level at atmospheric pressure without removing the pressure cap. It also provides some reserve coolant to compensate for minor leaks and evaporation or boiling losses. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Coolant Recovery Bottle - Removal Coolant Reservoir: Service and Repair Coolant Recovery Bottle - Removal GAS ENGINE 1. Partially drain cooling system using the draincock only See: Service and Repair. Drain system below level of the coolant recovery pressure container. 2. Remove the return hose (5) from the upper radiator hose tee (3). 3. Remove the coolant recovery bottle mount bolt (2) from the mounting bracket (1). 4. Disengage the coolant recovery container (6) from the washer reservoir bottle (4). 5. Remove the coolant recovery container (6). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Coolant Recovery Bottle - Removal > Page 2065 Coolant Reservoir: Service and Repair Coolant Recovery Bottle - Installation GAS ENGINE 1. Position the coolant recovery container (6) into the washer fluid reservoir (4). 2. Install the coolant recovery container mounting bolt (2). Tighten the mounting bolt to 4 Nm (35 in. lbs.). 3. Connect the hose (5) at the upper radiator tee (3). 4. Fill coolant recovery container to proper level. See: Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Radiator Cooling Fan Module C1 (Engine Compartment) 2 Way Radiator Cooling Fan Control Module: Diagrams Radiator Cooling Fan Module C1 (Engine Compartment) 2 Way Connector C1 - (ENGINE COMPARTMENT) 2 WAY FAN MODULE-RADIATOR COOLING - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Radiator Cooling Fan Module C1 (Engine Compartment) 2 Way > Page 2072 Radiator Cooling Fan Control Module: Diagrams Radiator Cooling Fan Module C2 (Engine Compartment) 2 Way Connector C2 - (ENGINE COMPARTMENT) 2 WAY FAN MODULE-RADIATOR COOLING - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2078 It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2079 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2080 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2081 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2082 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2083 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2084 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2085 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2086 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2087 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2088 Radiator Cooling Fan Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2089 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2090 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2091 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Radiator Fan Relays are located in the Fuse/Relay block. Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Low/High Connector - (IN F/RB) RELAY-RADIATOR FAN-LOW/HIGH - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High > Page 2097 Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Medium/High Connector - (IN F/RB) RELAY-RADIATOR FAN-MEDIUM/HIGH - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High > Page 2098 Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Series/Parallel Connector - (IN F/RB) RELAY-RADIATOR FAN-SERIES/PARALLEL - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 > Page 2104 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor 2 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 > Page 2105 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way > Page 2108 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 2 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 2 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2109 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. ENGINE COOLANT TEMPERATURE SENSOR WIRING OR CONNECTORS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2110 NOTE: Diagnose and repair any ECT circuit DTCs before proceeding with this test. NOTE: Allow the engine to cool to ambient temperature before proceeding. 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature sensor(s) and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Turn the ignition on. 5. Monitor the scan tool data relative to the sensor(s) and wiggle test the wiring and connectors. 6. Look for the data to change or for a DTC to set during the wiggle test. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. ENGINE COOLANT LEVEL AND CONDITION WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Check the engine coolant level and the condition of the engine coolant. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. THERMOSTAT WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Using the appropriate service information, determine the proper opening temperature of the thermostat. 2. With the scan tool, read the Engine Coolant Temperature Sensor value for each sensor. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 3. Monitor the sensor values on the scan tool. 4. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: Each thermostat should open at the temperature specified. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2111 Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. ENGINE COOLANT TEMPERATURE SENSOR NOTE: Allow the engine to cool to ambient temperature before proceeding. WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. With the scan tool, read the Engine Coolant Temperature Sensor value for each sensor. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 2. Monitor each sensor value on the scan tool and the actual coolant temperature with a thermometer. 3. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The sensor value transition should be smooth as the engine reaches operating temperature. The thermometer reading and the coolant temperature values on the scan tool should remain relatively close. Were any problems found? Yes - Go to 5. No - Test complete. 5. ECT SIGNAL CIRCUIT HIGH RESISTANCE NOTE: Perform this procedure for the sensor where erratic sensor values were detected in the previous test step. 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the ECT Signal circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 No - Repair the ECT Signal circuit for excessive resistance. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2112 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the Sensor Ground circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. ENGINE COOLANT TEMPERATURE SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Engine Coolant Temperature Sensor. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Description Heater Core: Description and Operation Description DESCRIPTION NOTE: LHD model shown. RHD model similar. The heater core (1) for the heating-A/C system is mounted within the HVAC air distribution housing, which is located behind the instrument panel. The heater core is a heat exchanger made of rows of tubes with fins and is positioned within the air distribution housing so that only the selected amount of air entering the housing passes through the heater core before it is distributed through the heating-A/C system ducts and outlets. One end of the heater core is fitted with a tank (2) that includes the fittings for the heater core tubes (3). The heater core can only be serviced by removing the HVAC housing from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Description > Page 2117 Heater Core: Description and Operation Operation OPERATION Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and it must be replaced if inoperative, leaking or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Installation Heater Core: Service and Repair Installation INSTALLATION NOTE: LHD model with A/C shown. RHD and heater-only models similar. 1. Carefully install the heater core (6) into the left side of the air distribution housing (5). 2. On RHD models, install the air distribution housing (5) onto the HVAC housing (9) See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/HVAC Housing - Installation. 3. Install the retaining bracket (4) and screw (3) that secure the heater core tubes (8). Tighten the screw to 1.2 Nm (10 in. lbs.) 4. Install the flange (2) that secures the heater core tubes to the front of the HVAC housing. 5. Install the screw (10) that secures the flange to the HVAC housing. Tighten the screw to 1.2 Nm (10 in. lbs.). NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 6. Install the foam seal (1) onto the flange. 7. Install the left side front floor duct See: Heating and Air Conditioning/Air Duct/Service and Repair/Floor Distribution Duct - Installation. NOTE: If the heater core is being replaced, flush the cooling system See: Service and Repair . 8. Install the HVAC housing assembly See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/HVAC Housing - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Installation > Page 2120 Heater Core: Service and Repair Removal REMOVAL NOTE: The HVAC housing assembly must be removed from vehicle for service of the heater core. NOTE: LHD model with A/C shown. RHD and heater-only models similar. 1. Remove the HVAC housing assembly and place it on a workbench See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/HVAC Housing - Removal. 2. Remove the left side front floor duct See: Heating and Air Conditioning/Air Duct/Service and Repair/Floor Distribution Duct - Removal. NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 3. Remove the foam seal (1) from the flange (2) located on the front of the HVAC housing (9). 4. Remove the screw (10) that secures the flange to the front of the HVAC housing and remove the flange. 5. Remove the screw (3) that secures the retaining bracket (4) for the heater core tubes (8) to the left side of the air distribution housing (5). 6. On RHD models, remove the air distribution housing from the HVAC housing See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/HVAC Housing - Removal 7. Carefully pull the heater core (6) out of the driver side of the air distribution housing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair > Removal Radiator Drain Plug: Service and Repair Removal REMOVAL CAUTION: Use of pliers on draincock is not recommended. Damage may occur to radiator or draincock. NOTE: It is not necessary to remove draincock during a routine coolant drain. 1. Remove the front passenger side wheel See: Maintenance/Wheels and Tires/Wheel Cover/Service and Repair/Wheel Cover - Removal 2. Remove the front passenger side splash shield assembly from the wheelhouse See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 3. Drain the cooling system See: Service and Repair. 4. Open the draincock (2) by turning it counterclockwise until it stops. 5. Turn the draincock (2) back (clockwise) 1/8 turn. 6. Pull the draincock (2) from the radiator tank (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair > Removal > Page 2126 Radiator Drain Plug: Service and Repair Installation INSTALLATION 1. Align draincock stem to radiator tank opening. 2. Push draincock (2) into the radiator tank opening. 3. Tighten the draincock (2) by turning clockwise until it stops. 4. Fill the cooling system See: Service and Repair 5. Install front passenger side splash shield assembly to the wheelhouse area See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 6. Install the front passenger side wheel See: Maintenance/Wheels and Tires/Wheel Cover/Service and Repair/Wheel Cover - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Radiator Cap - Description Radiator Cap: Description and Operation Radiator Cap - Description GAS ENGINE The cooling system is equipped with a pressure cap that releases built up pressure, maintaining a range of 97-124 kPa (14-18 psi). There is also a vent valve (6) in the center of the cap. This valve also opens when coolant is cooling and contracting, allowing coolant to return to radiator from coolant recovery container by vacuum through connecting hose. If valve is stuck shut, the radiator hoses will be collapsed on cool down. Clean the vent valve to ensure proper sealing when boiling point is reached. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Radiator Cap - Description > Page 2131 Radiator Cap: Description and Operation Radiator Cap - Operation GAS ENGINE The pressure cap allows the cooling system to operate at higher than atmospheric pressure. The higher pressure raises the coolant boiling point; this allows increased radiator cooling capacity. The secondary gasket in the cap seals the filler neck and the primary gasket seals the cooling system so that vacuum can be maintained, allowing coolant to be drawn back into the radiator from the reserve container. A vent valve in the center of the cap will remain shut as long as the cooling system is pressurized. As the coolant cools, it contracts and creates a vacuum in cooling system. This causes the vacuum valve to open and coolant in reserve/overflow tank to be drawn through connecting hose into radiator. If the vacuum valve is stuck shut, or overflow hose is kinked, radiator hoses will collapse on cool-down. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Pressure Testing Radiator Cap: Testing and Inspection Pressure Testing PRESSURE TESTING Dip the pressure cap in water. Clean any deposits off the vent valve or its seat and apply cap to end of the Pressure Cap Test Adaptor that is included with the Cooling System Tester 7700. Working the plunger, bring the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi), replace the pressure cap. CAUTION: The Cooling System Tester Tool is very sensitive to small air leaks that will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to the tool. Turn tool upside down and recheck pressure cap to confirm that cap is bad. If the pressure cap tests properly while positioned on Cooling System Tester 7700, but will not hold pressure or vacuum when positioned on the filler neck. Inspect the filler neck and cap top gasket for irregularities that may prevent the cap from sealing properly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Pressure Testing > Page 2134 Radiator Cap: Testing and Inspection Pressure Relief Test PRESSURE RELIEF TESTING WARNING: If vehicle has been run recently, wait 15 minutes before removing cap. Place a shop towel over the cap, and without pushing down, rotate it counterclockwise to the first stop. Allow fluids to escape through the overflow tube. When the system stops pushing coolant and steam into the coolant recovery container and pressure drops, push down on the cap and remove it completely. Squeezing the radiator inlet hose with a shop towel (to check pressure) before and after turning to the first stop is recommended. WARNING: The warning words "do not open hot" on the pressure cap is a safety precaution. When hot, the cooling system builds up pressure. To prevent scalding or other injury, the pressure cap should not be removed while the system is hot and/or under pressure. The pressure cap upper gasket to filler neck seal can be checked by removing the overflow hose at the radiator filler neck overflow nipple. Attach the radiator pressure tester to the filler neck overflow nipple, and pump air into the system. The pressure cap upper gasket should relieve pressure at 69-124 kPa (10-18 psi), and hold pressure at 55 kPa (8 psi) minimum. There is no need to remove the pressure cap at any time except for the following purposes: - Check and adjust coolant freeze point - Refill system with new coolant - Conducting service procedures - Checking for leaks Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Service and Repair > Radiator Cap - Cleaning Radiator Cap: Service and Repair Radiator Cap - Cleaning CLEANING Use only a mild soap to clean the pressure cap. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Service and Repair > Radiator Cap - Cleaning > Page 2137 Radiator Cap: Service and Repair Radiator Cap - Inspection INSPECTION Hold the cap in your hand, top side up. The vent valve (6) at the bottom of the cap should not open. If the valve opens, replace the cap. If the rubber seal (5) has swollen, preventing the valve from opening, replace the cap. Hold the cleaned cap in your hand, upside down. If any light can be seen between vent valve (6) and the rubber seal (5), replace the cap. A replacement cap must be of the type designed for a full pressure coolant systems. This design ensures coolant return to the radiator. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Radiator Cooling Fan Module C1 (Engine Compartment) 2 Way Radiator Cooling Fan Control Module: Diagrams Radiator Cooling Fan Module C1 (Engine Compartment) 2 Way Connector C1 - (ENGINE COMPARTMENT) 2 WAY FAN MODULE-RADIATOR COOLING - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Radiator Cooling Fan Module C1 (Engine Compartment) 2 Way > Page 2144 Radiator Cooling Fan Control Module: Diagrams Radiator Cooling Fan Module C2 (Engine Compartment) 2 Way Connector C2 - (ENGINE COMPARTMENT) 2 WAY FAN MODULE-RADIATOR COOLING - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Radiator Fan Relays are located in the Fuse/Relay block. Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Low/High Connector - (IN F/RB) RELAY-RADIATOR FAN-LOW/HIGH - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High > Page 2150 Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Medium/High Connector - (IN F/RB) RELAY-RADIATOR FAN-MEDIUM/HIGH - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan-Low/High > Page 2151 Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan-Series/Parallel Connector - (IN F/RB) RELAY-RADIATOR FAN-SERIES/PARALLEL - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 > Page 2158 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor 2 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 > Page 2159 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way > Page 2162 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 2 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 2 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2163 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. ENGINE COOLANT TEMPERATURE SENSOR WIRING OR CONNECTORS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2164 NOTE: Diagnose and repair any ECT circuit DTCs before proceeding with this test. NOTE: Allow the engine to cool to ambient temperature before proceeding. 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature sensor(s) and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Turn the ignition on. 5. Monitor the scan tool data relative to the sensor(s) and wiggle test the wiring and connectors. 6. Look for the data to change or for a DTC to set during the wiggle test. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. ENGINE COOLANT LEVEL AND CONDITION WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Check the engine coolant level and the condition of the engine coolant. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. THERMOSTAT WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Using the appropriate service information, determine the proper opening temperature of the thermostat. 2. With the scan tool, read the Engine Coolant Temperature Sensor value for each sensor. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 3. Monitor the sensor values on the scan tool. 4. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: Each thermostat should open at the temperature specified. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2165 Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. ENGINE COOLANT TEMPERATURE SENSOR NOTE: Allow the engine to cool to ambient temperature before proceeding. WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. With the scan tool, read the Engine Coolant Temperature Sensor value for each sensor. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 2. Monitor each sensor value on the scan tool and the actual coolant temperature with a thermometer. 3. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The sensor value transition should be smooth as the engine reaches operating temperature. The thermometer reading and the coolant temperature values on the scan tool should remain relatively close. Were any problems found? Yes - Go to 5. No - Test complete. 5. ECT SIGNAL CIRCUIT HIGH RESISTANCE NOTE: Perform this procedure for the sensor where erratic sensor values were detected in the previous test step. 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the ECT Signal circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 No - Repair the ECT Signal circuit for excessive resistance. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2166 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the Sensor Ground circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. ENGINE COOLANT TEMPERATURE SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Engine Coolant Temperature Sensor. - Perform the PCM Verification Test.See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications ENGINE COOLING THERMOSTAT Primary Thermostat: Begins opening................................................................................................... ............................................................................................82 °C ( 179 °F). Fully open....................... .............................................................................................................................................................. ....................95 °C (203 °F). Secondary Thermostat: Begins opening.............................................................................................. ...................................................................................................95 °C (203 °F). Fully open................. .............................................................................................................................................................. ........................110 °C (230 °F). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Engine Coolant Thermostat - Description Thermostat: Description and Operation Engine Coolant Thermostat - Description DESCRIPTION The primary thermostat is located on the front of the water plenum in the thermostat housing/coolant inlet. The thermostat has an air bleed vent located on its flange. The air bleed vent (1) and the locator dimple on thermostat seal provide for proper positioning of thermostat in inlet housing. The secondary thermostat is located in the cylinder head under the water plenum. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Engine Coolant Thermostat - Description > Page 2172 Thermostat: Description and Operation Engine Coolant Thermostat - Operation OPERATION When the Engine is cold and both the primary and secondary thermostats are closed. The coolant will circulate through the engine, heater system, and the bypass. The cooling system has no flow through the radiator As the engine warms up, the primary thermostat will start to open at 82 °C ( 179 °F). Coolant will start to flow through the radiator oil cooler and transmission cooler. Coolant will flow through the transmission oil cooler only when the primary thermostat is fully open. The primary thermostat will fully open at 95 °C (203 °F). The secondary thermostat will start to open at 95 °C (203 °F). This will increase the coolant flow through the cylinder block and cylinder head and the radiator. The secondary thermostat will fully open at 110 °C (230 °F). If the thermostat is stuck open or allows coolant leakage through it, the engine will not operate at the proper temperature for obtaining engine fuel efficiency, performance and emissions levels. If this condition occurs, a diagnostic trouble code will be set and a MIL light will be turned on. Refer to the Powertrain Diagnostic Procedures manual for further information and diagnostics provided. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Page 2173 Thermostat: Testing and Inspection ENGINE COOLANT THERMOSTAT The thermostat is operated by a wax filled chamber (pellet) which is sealed. When heated coolant reaches a predetermined temperature the wax pellet expands enough to overcome the closing spring and water pump pressure, which forces the valve to open. Coolant leakage into the pellet will cause a thermostat to fail open. Do not attempt to free up a thermostat with a screwdriver. Thermostat diagnostics is included in Totally Integrated Power Module's (TIPM) programming for on-board diagnosis. The malfunction indicator light (MIL) will illuminate and a diagnostic trouble code (DTC) will be set when an "open too soon" condition occurs. Do not change a thermostat for lack of heater performance or temperature gauge position, unless a DTC is present. For other probable causes, See: Testing and Inspection. Thermostat failing shut is the normal long term mode of failure, and normally, only on high mileage vehicles. The temperature gauge will indicate this. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Engine Coolant Thermostat - Removal Thermostat: Service and Repair Engine Coolant Thermostat - Removal Primary Thermostat PRIMARY THERMOSTAT - GAS ENGINE 1. Partially drain THE cooling system See: Service and Repair. 2. Remove THE air filter housing See: Service and Repair 3. Disconnect the coolant hose (1) from the inlet housing (2). 4. Remove inlet housing bolts (3). 5. Remove the thermostat assembly, and clean the sealing surfaces. Secondary Thermostat SECONDARY THERMOSTAT - GAS ENGINE 1. Partially drain cooling system.See: Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Engine Coolant Thermostat - Removal > Page 2176 2. Remove the air filter housing See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body Removal. 3. Disconnect coolant hoses (1) from rear of the coolant adapter (2). 4. Remove the radiator hose (3). 5. Remove the radiator hose (4) from the front of the coolant adapter (2). 6. Remove the coolant adapter mounting bolts. 7. Carefully slide the coolant adapter off the water pump inlet tube and remove the coolant adapter (2) and the secondary thermostat. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Engine Coolant Thermostat - Removal > Page 2177 Thermostat: Service and Repair Engine Coolant Thermostat - Installation Primary Thermostat PRIMARY THERMOSTAT - GAS ENGINE 1. Position thermostat into the water plenum, aligning air bleed with the location notch on inlet housing (2). 2. Install inlet housing (2) onto coolant adapter. Tighten bolts to 9 Nm (79 in. lbs.). 3. Connect coolant hose (1). 4. Install air filter housing. 5. Fill cooling system See: Service and Repair. Secondary Thermostat SECONDARY THERMOSTAT - GAS ENGINE 1. Position the thermostat into the cylinder head. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Engine Coolant Thermostat - Removal > Page 2178 2. Inspect the water pump inlet tube O-rings for damage before installing the tube in the coolant adapter. Replace O-ring as necessary. 3. Lubricate the O-rings with soapy water. 4. Position the coolant adapter on the water pump inlet tube and the cylinder head. 5. Install the coolant adapter mounting bolts. Tighten the bolts to 18 Nm (159 in. lbs.). 6. Connect the front coolant hose (1). 7. Connect the two rear coolant hoses (1). 8. Connect the radiator hose (3). 9. Install the air filter housing See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body Installation 10. Fill the cooling system See: Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications WATER PUMP Water Pump - Bolts.............................................................................................................................. ......................................................24 Nm (18 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2182 Water Pump: Description and Operation GAS ENGINE The water pump (3) on the world engine is attached to the water pump adapter on the front of the cylinder block. The water pump is driven by the accessory drive belt. The water pump is connected to the water plenum by the return tube. Turbocharger equipped engines use a smaller diameter water pump pulley then the naturally a separated engine. This allows increased coolant flow without pump cavation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2183 Water Pump: Testing and Inspection WATER PUMP A quick flow test to determine if the water pump is working effectively is to check heater system for proper operation. A defective pump will not provide an adequate flow of heated coolant through the system. WARNING: DO NOT REMOVE THE COOLING SYSTEM PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. Another flow test to help determine water pump operation is as follows: 1. Remove cooling system pressure cap. 2. Remove a small amount of coolant from the system. 3. Start the engine and warm up until thermostat opens. 4. With the thermostat open and coolant level low, visually inspect for coolant flow. If flow is present, the water pump is pumping coolant through the system. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures Water Pump: Procedures Water Pump - Coolant Air Evacuation COOLANT AIR EVACUATION Evacuating or purging air from the cooling system involves the use of a pressurized air operated vacuum generator. The vacuum created allows for a quick and complete coolant refilling while removing any airlocks present in the system components. NOTE: To avoid damage to the cooling system, ensure that no component would be susceptible to damage when a vacuum is drawn on the system. WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASED COOLANT PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE; PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED; PERSONAL INJURY CAN RESULT. WARNING: WEAR APPROPRIATE EYE AND HAND PROTECTION WHEN PERFORMING THIS PROCEDURE. NOTE: The service area where this procedure is performed should have a minimum shop air requirement of 80 PSI (5.5 bar) and should be equipped with an air dryer system. NOTE: For best results, the radiator should be empty. The vehicle's heater control should be set to the heat position (ignition may need to be turned to the on position but do not start the motor). 1. Refer to the Chrysler Pentastar Service Equipment (Chrysler PSE) Coolant Refiller #85-15-0650 or equivalent tool's operating manual for specific assembly steps. 2. Choose an appropriate adapter cone that will fit the vehicle's radiator filler neck or reservoir tank. 3. Attach the adapter cone (2) to the vacuum gauge (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2186 4. Make sure the vacuum generator/venturi ball valve (3) is closed and attach an airline hose (2) (minimum shop air requirement of 80 PSI/5.5 bar) to the vacuum generator/venturi (1). 5. Position the adaptor cone/vacuum gauge assembly into the radiator filler neck or reservoir tank. Ensure that the adapter cone is sealed properly. 6. Connect the vacuum generator/venturi (2) to the positioned adaptor cone/vacuum gauge assembly (1). 7. Open the vacuum generator/venturi ball valve. NOTE: Do not bump or move the assembly as it may result in loss of vacuum. Some radiator overflow hoses may need to be clamped off to obtain vacuum. 8. Let the system run until the vacuum gauge shows a good vacuum through the cooling system. Refer to the tool's operating manual for appropriate pressure readings. NOTE: If a strong vacuum is being created in the system, it is normal to see the radiator hoses to collapse. 9. Close the vacuum generator/venturi ball valve. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2187 10. Disconnect the vacuum generator/venturi and airline from the adaptor cone/vacuum gauge assembly. 11. Wait approximately 20 seconds, if the pressure readings do not move, the system has no leaks. If the pressure readings move, a leak could be present in the system and the cooling system should be checked for leaks and the procedure should be repeated. 12. Place the tool's suction hose into the coolant's container. NOTE: Ensure there is a sufficient amount of coolant, mixed to the required strength/protection level available for use. For best results and to assist the refilling procedure, place the coolant container at the same height as the radiator filler neck. Always draw more coolant than required. If the coolant level is too low, it will pull air into the cooling system which could result in airlocks in the system. 13. Connect the tool's suction hose (1) to the adaptor cone/vacuum gauge assembly (2). 14. Open the suction hose's ball valve to begin refilling the cooling system. 15. When the vacuum gauge reads zero, the system is filled. NOTE: On some remote pressurized tanks, it is recommended to stop filling when the proper level is reached. 16. Close the suction hose's ball valve and remove the suction hose from the adaptor cone/vacuum gauge assembly. 17. Remove the adaptor cone/vacuum gauge assembly from the radiator filler neck or reservoir tank. 18. With heater control unit in the HEAT position, operate engine with container cap in place. 19. After engine has reached normal operating temperature, shut engine off and allow it to cool. When engine is cooling down, coolant will be drawn into the radiator from the pressure container. 20. Add coolant to the recovery bottle/container as necessary. Only add coolant to the container when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion. Add necessary coolant to raise container level to the COLD MINIMUM mark after each cool down period. 21. Once the appropriate coolant level is achieved, attach the radiator cap or reservoir tank cap. Water Pump - Inspection WATER PUMP Replace water pump body assembly if it has any of these defects: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2188 - Cracks or damage on the body. - Coolant leaks from the shaft seal, evident by wet coolant traces on the pump body. - Loose or rough turning bearing. - Impeller rubs either the pump body or the engine block. - Impeller loose or damaged. - Sprocket or sprocket flange loose or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2189 Water Pump: Removal and Replacement Water Pump - Removal GAS ENGINE 1. Remove the accessory drive belt See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. 2. Raise vehicle See: Maintenance/Vehicle Lifting/Service and Repair. 3. Remove accessory drive belt splash shield. 4. Drain cooling system See: Service and Repair. 5. Remove screws attaching water pump pulley (1). Remove pulley (1). 6. Remove water pump mounting bolts (2). 7. Remove water pump (3). Water Pump - Disassembly WATER PUMP - GAS ENGINE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2190 1. Remove the water pump assembly from the vehicle.See: Water Pump - Removal 2. Discard the water pump outlet gasket (7). 3. Remove the three bolts (1) attaching the water pump pulley (2) to the water pump (4). 4. Remove the water pump pulley (2). 5. Remove the five bolts (3) attaching the water pump (4) to the water pump adapter (6). 6. Remove and discard the gasket (8). 7. Remove the water pump (4) and inspect carefully for any damage. See: Procedures/Water Pump Inspection Water Pump - Assembly WATER PUMP - GAS ENGINE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2191 1. Throughly clean all gasket mating surfaces before assembling. 2. Inspect water pump and components for any damage.See: Procedures/Water Pump - Inspection 3. Using bolts (3), install the water pump (4) and gasket (8) to the water pump adapter (6). Tighten the bolts (3) to 22 N-m (16 lbs. ft.) 4. Using bolts (1), install the water pump pulley (2) to the water pump (4). Tighten the bolts (1) to 9 N-m (80 lbs. in.) 5. Using bolts (5), install the water pump assembly and gasket to the engine block. Tighten the bolts to 24 Nm (18 lbs. ft.).See: Water Pump Installation 6. Start the engine and check for leaks.See: Testing and Inspection Water Pump - Installation GAS ENGINE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2192 1. Position the water pump assembly (1) and gasket onto the cylinder block. 2. Position the water inlet tube (4) and gasket onto the water pump (1). 3. Install the mounting bolts (2). Tighten the bolts to 24 Nm (18 ft. lbs.). 4. Install the drive belt splash shield. 5. Lower the vehicle. 6. Install the accessory drive belt See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation. 7. Evacuate air and refill cooling system.See: Procedures/Water Pump - Coolant Air Evacuation 8. Check cooling system for leaks.See: Testing and Inspection Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Remove engine cover. 2. Disconnect and isolate negative batter cable. 3. Disconnect upstream DPF temperature sensor electrical connector. 4. Remove upstream DPF temperature sensor. 5. Disconnect downstream DPF temperature sensor electrical connector. 6. Remove downstream DPF temperature sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 2199 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Position DPF downstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 2. Connect downstream temperature sensor electrical connector. 3. Position DPF upstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 4. Connect upstream temperature sensor electrical connector. 5. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications EXHAUST MANIFOLD Exhaust Manifold-Bolts......................................................................................................................... ......................................................34 Nm (25 ft. lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures Exhaust Manifold: Procedures Exhaust Manifold - Cleaning CLEANING 1. Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head. Exhaust Manifold - Inspection INSPECTION 1. Inspect manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 in. per foot) of manifold length. 2. Inspect manifolds for cracks or distortion. Replace manifold as necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2205 Exhaust Manifold: Removal and Replacement Exhaust Manifold - Removal REMOVAL 1. Remove engine cover (1). 2. Disconnect negative cable from battery. 3. Remove bolts attaching upper heat shield. 4. Remove upper heat shield. 5. Disconnect exhaust pipe from manifold. 6. Remove manifold support bracket (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2206 7. Remove exhaust manifold heat shield (1). 8. Disconnect oxygen sensor electrical connector. 9. Remove exhaust manifold retaining fasteners. 10. Remove and discard manifold gasket. Exhaust Manifold - Installation INSTALLATION 1. Install a new exhaust manifold gasket DO NOT APPLY SEALER. 2. Tighten the exhaust manifold bolts to 34 Nm (25 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2207 3. Install exhaust manifold heat shields. Tighten bolts to 12 Nm (105 in. lbs.). 4. Install exhaust manifold support bracket (2). 5. Install new catalytic converter gasket. 6. Install exhaust pipe to manifold (1). Tighten fasteners to 28 Nm (250 in. lbs.). 7. Connect oxygen sensor electrical connector (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2208 8. Connect negative cable to battery (3). 9. Install engine cover (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Removal Exhaust Pipe/Muffler Hanger: Service and Repair Removal REMOVAL 1. Disconnect isolator from exhaust system component. 2. Remove screws attaching isolator bracket to underbody. 3. Remove isolator assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Removal > Page 2213 Exhaust Pipe/Muffler Hanger: Service and Repair Installation INSTALLATION 1. Position isolator bracket to underbody and install attaching screws. Tighten bracket screws to frame rail to 8.5 Nm (75 in. lbs.) and bracket screws to the rear panel to 3.7 Nm (33 in. lbs.). 2. Connect isolator to exhaust system component. 3. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. 4. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Sensor: Service and Repair Removal EXHAUST PRESSURE SENSOR 1. Disconnect and isolate negative battery cable. 2. Remove electrical connector at pressure differential sensor (2). 3. Remove upstream exhaust pressure tube (4) from catalytic converter 4. Remove downstream pressure tube (6) from catalytic converter. 5. Remove pressure differential sensor mounting bolt. 6. Remove pressure differential sensor (2) and tubing (7) from vehicle. 7. Remove tubing (7) from pressure differential sensor (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal > Page 2218 Exhaust Pressure Sensor: Service and Repair Installation EXHAUST PRESSURE SENSOR 1. Install tubing (7) on pressure differential sensor (2). 2. Position pressure differential sensor (2) and tubing (7). 3. Install pressure differential sensor mounting bolt (3). Tighten to 10 Nm (89 in. lbs.). 4. Install downstream pressure tube (6) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.). 5. Install upstream pressure tube (4) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.) 6. Position electrical connector (1) into bracket. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation Heat Shield: Description and Operation DESCRIPTION Heat shields (1), are needed to protect both the vehicle and the environment from the high temperatures developed in the vicinity of the catalytic converter. CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shield. Light over-spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal Heat Shield: Service and Repair Removal REMOVAL 1. Raise vehicle on hoist. 2. Remove fasteners attaching heat shield. 3. Remove heat shield(s) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal > Page 2224 Heat Shield: Service and Repair Installation INSTALLATION 1. Position heat shield(s) to underbody. 2. Install heat shield fasteners. 3. Inspect heat shield to exhaust system clearances and adjust as necessary. 4. Lower vehicle. 5. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. 6. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal Muffler: Service and Repair Removal REMOVAL WARNING: The normal operating temperature of the exhaust system is very high. Therefore, never work around or attempt to service any part of the exhaust system until it is cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operating time. NOTE: When replacement is required on any component of the exhaust system, you must use original equipment parts (or their equivalent). 1. Raise vehicle on hoist and apply penetrating oil to band clamp nut and bolt of component being removed. NOTE: Do not use petroleum-based lubricants when removing/installing muffler or exhaust pipe isolators (3) as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and water. 2. Remove exhaust system ground strap (1) at rear of I-Pipe/Muffler assembly (2). 3. Loosen band clamp and remove support isolators (3) at I-Pipe/Muffler assembly (2). Remove I-Pipe/Muffler assembly (2) from catalytic converter . 4. Clean ends of pipes and muffler to assure mating of all parts. Discard broken or worn isolators, rusted or overused clamps, supports, and attaching parts. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal > Page 2229 Muffler: Service and Repair Installation INSTALLATION When assembling exhaust system do not tighten clamp until components are aligned and clearances are checked. 1. Install the I-Pipe/Muffler assembly to catalytic converter and the isolator supports to the underbody. 2. Working from the front of system; align each component to maintain position and proper clearance with underbody parts. Tighten band clamp to 55 Nm (40 ft. lbs.). CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clamp band has been stretched and has lost its clamping force and must be replaced. To replace the band clamp; remove the nut and peel back the ends of the clamp until spot weld breaks. File or grind remaining weld material until pipe surface is smooth. NOTE: Maintain proper clamp orientation when replacing with new clamp. 3. Connect the exhaust system ground strap. 4. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. 5. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Sensor: Service and Repair Removal EXHAUST PRESSURE SENSOR 1. Disconnect and isolate negative battery cable. 2. Remove electrical connector at pressure differential sensor (2). 3. Remove upstream exhaust pressure tube (4) from catalytic converter 4. Remove downstream pressure tube (6) from catalytic converter. 5. Remove pressure differential sensor mounting bolt. 6. Remove pressure differential sensor (2) and tubing (7) from vehicle. 7. Remove tubing (7) from pressure differential sensor (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal > Page 2235 Exhaust Pressure Sensor: Service and Repair Installation EXHAUST PRESSURE SENSOR 1. Install tubing (7) on pressure differential sensor (2). 2. Position pressure differential sensor (2) and tubing (7). 3. Install pressure differential sensor mounting bolt (3). Tighten to 10 Nm (89 in. lbs.). 4. Install downstream pressure tube (6) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.). 5. Install upstream pressure tube (4) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.) 6. Position electrical connector (1) into bracket. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Remove engine cover. 2. Disconnect and isolate negative batter cable. 3. Disconnect upstream DPF temperature sensor electrical connector. 4. Remove upstream DPF temperature sensor. 5. Disconnect downstream DPF temperature sensor electrical connector. 6. Remove downstream DPF temperature sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 2240 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Position DPF downstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 2. Connect downstream temperature sensor electrical connector. 3. Position DPF upstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 4. Connect upstream temperature sensor electrical connector. 5. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2252 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2253 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2254 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2255 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2256 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2257 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2258 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2259 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2260 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2261 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2262 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: Recalls Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P0139/P0571 Set NUMBER: 18-018-09 GROUP: Vehicle Performance DATE: June 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For Diagnostic Trouble Code P0139 Or P0571 Is Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey 2009 (JS) Sebring/Avenger/Sebring Convertible 2009 (PM) Caliber 2009 (MK) Compass/Patriot NOTE: This bulletin applies to: - 2009 JS vehicles equipped with a 2.0L/2.4L Engine (Sales Code ECN or EDG or ED3) built before July 27, 2009 (MDH 0727XX) - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before July 27, 2009 (MDH 0727XX) - 2009 PM/MK vehicles equipped with a 1.8L, 2.0L or 2.4L engines (Sales Codes EBA, ECN and ED3) built before July 10, 2009 (MDH 0710XX) SYMPTOM/CONDITION: Some customers may experience a MIL illumination. The MIL is for P0139 - 02 Sensor 1/2 Slow Response. Further investigation by the technician may also find DTC P0571. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other then the ones listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set > Page 2272 If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0139/P0571 Set NUMBER: 18-018-09 GROUP: Vehicle Performance DATE: June 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For Diagnostic Trouble Code P0139 Or P0571 Is Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey 2009 (JS) Sebring/Avenger/Sebring Convertible 2009 (PM) Caliber 2009 (MK) Compass/Patriot NOTE: This bulletin applies to: - 2009 JS vehicles equipped with a 2.0L/2.4L Engine (Sales Code ECN or EDG or ED3) built before July 27, 2009 (MDH 0727XX) - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before July 27, 2009 (MDH 0727XX) - 2009 PM/MK vehicles equipped with a 1.8L, 2.0L or 2.4L engines (Sales Codes EBA, ECN and ED3) built before July 10, 2009 (MDH 0710XX) SYMPTOM/CONDITION: Some customers may experience a MIL illumination. The MIL is for P0139 - 02 Sensor 1/2 Slow Response. Further investigation by the technician may also find DTC P0571. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other then the ones listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set > Page 2278 If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2283 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2284 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2285 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2286 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2287 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2288 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2289 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2290 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2291 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2292 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2293 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: All Technical Service Bulletins Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0139/P0571 Set NUMBER: 18-018-09 GROUP: Vehicle Performance DATE: June 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For Diagnostic Trouble Code P0139 Or P0571 Is Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey 2009 (JS) Sebring/Avenger/Sebring Convertible 2009 (PM) Caliber 2009 (MK) Compass/Patriot NOTE: This bulletin applies to: - 2009 JS vehicles equipped with a 2.0L/2.4L Engine (Sales Code ECN or EDG or ED3) built before July 27, 2009 (MDH 0727XX) - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before July 27, 2009 (MDH 0727XX) - 2009 PM/MK vehicles equipped with a 1.8L, 2.0L or 2.4L engines (Sales Codes EBA, ECN and ED3) built before July 10, 2009 (MDH 0710XX) SYMPTOM/CONDITION: Some customers may experience a MIL illumination. The MIL is for P0139 - 02 Sensor 1/2 Slow Response. Further investigation by the technician may also find DTC P0571. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other then the ones listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set > Page 2303 If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2309 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2310 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2311 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2312 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2313 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2314 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2315 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2316 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2317 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2318 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2319 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: All Technical Service Bulletins Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2324 Engine Control Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2325 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way Engine Control Module: Diagrams Powertrain Control Module C1 (Engine Compartment) 58 Way Connector C1 (GAS) - (ENGINE COMPARTMENT) 58 WAY MODULE-POWERTRAIN CONTROL (GAS) - (ENGINE COMPARTMENT) 58 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2328 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2329 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2330 Engine Control Module: Diagrams Powertrain Control Module C2 (Engine Compartment) 96 Way Connector C2 (GAS) - (ENGINE COMPARTMENT) 96 WAY MODULE-POWERTRAIN CONTROL (GAS) - (ENGINE COMPARTMENT) 96 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2331 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2332 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2333 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description Engine Control Module: Description and Operation Powertrain Control Module - Description Sensor Return - PCM Input SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). PCM Ground PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded separately from the ground pins. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 2336 Engine Control Module: Description and Operation Powertrain Control Module - Operation Operation OPERATION The PCM supplies two regulated 5 volts supplies - a 5V primary and a 5V secondary (auxiliary) to the following sensors: - Camshaft Position Sensor (5V secondary) - Crankshaft Position Sensor (5V primary) - EGR Position feedback sensor (5V secondary) (if equipped) - Engine coolant temperature sensor (connected to 5V internal via a pull-up resistor) - Inlet Air Temperature Sensor (connected to 5V internal via a pullup resistor) - Knock sensor (connected to 5V internal via a pullup resistor) - Manifold absolute pressure sensor (5V secondary) - Oil Pressure Switch (connected to 5V internal via pullup resistor) - Pedal Value Sensor #1 (5V Primary) - Pedal Value Sensor #2 (5V Secondary) - SRV Position Feedback Sensor (5V Secondary) - Throttle Position Sensors (5V Primary) - Variable Line Pressure Sensor (5V Secondary) Powertrain Control Module POWERTRAIN CONTROL MODULE The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. NOTE: PCM Inputs: - Air Conditioning Controls - Battery Voltage - Brake Switch - Camshaft Position Sensor - Clutch Upstop Switch - Clutch Interlock - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor (Bus message) - Ignition Switch - Intake Air Temperature Sensor - Knock Sensor - Evaporative System Integrity Monitor Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 2337 - Manifold Absolute Pressure (MAP) Sensor - Oil Pressure Switch - Oxygen Sensors - Power Steering Pressure Switch - Speed Control Switches - Vehicle Speed Sensor (MTX-equipped models) NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Charging Indicator Lamp (Bus Message) - Proportional Purge Solenoid - Fuel Injectors - Generator Field - Ignition Coils - Malfunction Indicator (Check Engine) Lamp (Bus Message) - Manifold Flow Valve - Oxygen Sensors Heater Controls - Variable Valve Timing - Vehicle Speed (Manual Transmission) Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and EVAP canister purge operation. The PCM also determines the appropriate transmission shift schedule and shift points, depending on the present operating conditions and driver demand. The PCM regulates the cooling fan, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM also performs diagnostics. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. - Battery voltage - Coolant temperature - Exhaust gas content (oxygen sensor) - Engine speed (crankshaft position sensor) - Intake air temperature - Manifold absolute pressure - Throttle position The PCM adjusts ignition timing based on the following inputs. - Coolant temperature - Engine speed (crankshaft position sensor) - Knock sensor - Manifold absolute pressure - Throttle position - Transmission gear selection (park/neutral switch) - Intake air temperature The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs. - Air conditioning sense - Battery voltage - Brake switch - Coolant temperature - Engine speed (crankshaft position sensor) - Engine run time - Manifold absolute pressure - Power steering pressure switch - Throttle position - Transmission gear selection (park/neutral switch) - Vehicle distance (speed) The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive the signal within approximately 1 second of engine cranking, it deactivates the fuel pump. When these are deactivated, power is shut off to the fuel injectors, ignition coils, oxygen sensor heating elements and fuel pump. The PCM contains a voltage converter that changes battery voltage to a regulated 5 volts direct current to power the camshaft position sensor, crankshaft position sensor, manifold absolute pressure sensor, throttle position sensor, A/C pressure switch, A/C pressure transducer, and vehicle speed sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures TCM Initialization TRANSMISSION CONTROL MODULE INITIALIZATION NOTE: Refer to the following table when the Transmission Control Module (TCM) and/or transaxle has been replaced to determine if the TCM memory must be erased. INITIAL LEARN (BRAND-NEW MODULE, MEMORY ALREADY CLEAR) Battery must be connected. If the Totally Integrated Power Module (TIPM) is to be configured, configure the TIPM and then turn ignition key to OFF/LOCKED briefly, then back to RUN. The shifter must be in PARK or NEUTRAL, engine not running. 1. Turn the ignition key to RUN for 4 seconds to allow reading of new values. 2. Turn ignition key to OFF/LOCKED for 2 seconds to allow storing new values in EEROM. 3. Turn the ignition key to RUN, with scan tool clear DTCs. 4. Turn ignition key to OFF/LOCKED for 2 seconds. 5. After at least 7 seconds, read DTCs. 6. If DTCs resets See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Testing and Inspection RELEARN, AFTER REPLACING A TRANSAXLE 1. Turn ignition key to RUN. 2. Clear learning memory using the scan tool. 3. Turn the ignition key to OFF/LOCKED for 2 seconds. 4. Turn the ignition key to RUN Clear DTCs. 5. Turn the ignition key to OFF/LOCKED for 2 seconds. 6. Turn ignition key to RUN. 7. After at least 7 seconds, read DTCs. 8. If DTCs resets See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Testing and Inspection PCM/TCM Reprogramming PCM / TCM PROGRAMMING PCM / TCM FLASH PROGRAMING This procedure will need to be done when one or more of the following situations are true: 1. A vehicle's Powertrain Control Module (PCM) has been replaced. 2. A diagnostic trouble code (DTC) is set P1602 - PCM Not Programmed. 3. An updated calibration or software release is available for either the PCM or TCM ECUs. This procedure assumes that the wiTECH(TM) Vehicle Connection Interface (VCI) pod, StarSCAN(R) and StarMOBILE(R) devices are configured to your dealership's network with either a wired or wireless connection. The wiTECH(TM) VCI pod, StarSCAN(R) and StarMOBILE(R) must also be running at the latest operating system and software release level. For more help on how to network your StarSCAN(R) or StarMOBILE(R) reference the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the Download Center. For the wiTECH(TM) VCI pod use the "HELP" tab in the wiTECH(TM) Diagnostic Application. Table of contents 1. SECTION 1 - PCM / TCM FLASH PROCEDURE SECTION 1 - PCM / TCM FLASH PROCEDURE 2. REQUIRED TOOLS/EQUIPMENT REQUIRED TOOLS/EQUIPMENT: 3. TECH TIPS and INFORMATION TECH TIPS and INFORMATION: 4. PARTS REQUIRED PARTS REQUIRED Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2340 SECTION 1 - PCM / TCM FLASH PROCEDURE If using StarSCAN(R) or StarMOBILE(R) Desktop Client. Go To REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client If using StarMOBILE(R) Standalone Diagnostic Mode. Go To REPAIR PROCEDURE wiTECH(TM) Diagnostic Application REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the StarSCAN(R) or StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power on the StarSCAN(R) or StarMOBILE(R). If the StarMOBILE(R) is being used, launch the StarMOBILE(R) Desktop Client and connect to the appropriate StarMOBILE(R) device. 4. Retrieve the old ECU part number. From the tool's Home screen, a. Select "ECU View" b. Select "PCM/ECM" c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the Flash PCM/ECM screen for later reference. 5. Program the ECU as follows: a. Using the StarSCAN(R) / StarMOBILE(R) at the Home screen, select "ECU View" b. Select "PCM/ECM" c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File" and follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 4e, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. g. Select "Download to Scantool" h. Once the download is complete, select "Close" and then "Back" i. Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. j. When the PCM/ECM update is complete, select "OK" k. Verify that the part number at the top of the Flash PCM/ECM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 6. Continue to SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced. 7. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See Section 3 SECTION 3 - AUTHORIZED MODIFICATION LABEL for details). REPAIR PROCEDURE - wiTECH(TM) Diagnostic Application NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the wiTECH(TM) Vehicle Connection Interface (VCI) pod to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Launch the wiTECH(TM) Diagnostic Application and connect to the appropriate wiTECH(TM) device. 4. From the wiTECH(TM) Diagnostic Application Home screen, a. Select "HELP" b. Select "HELP CONTENTS" c. Follow the correct "HELP TOPIC" for the ECU being programmed SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES NOTE: Find the PCM/TCM Type for the vehicle, read and write down the steps, and then go to the step by step instructions for additional information on how to perform these procedures. STEP-BY-STEP INSTRUCTIONS If an EDC16-U31 PCM/ECM (2.0L) was replaced, perform the following additional steps and/or routines: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2341 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Program Variant Code If an EDC16-C2 PCM/ECM (2.2L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. IMA Rapid Calibration Test - Only on 06 PT AND up 4. Injector Quantity Adjustment - Only on 06 PT AND up If an EDC16-CP31 (3.0L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Diesel Particulate Filter (Used) Learning 4. NOx Catalyst (New) Initialization 5. Injector Quantity Adjustment 6. IMA Rapid Calibration Test 7. Fuel Mean Value Adaptation Initialization 8. Exhaust Throttle Plate Adaptive Learn Position If an EDC16-CP31-2 (2.8L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Injector Quantity Adjustment 4. Program Variant Code 5. ECU Replacement With Value Transfer if the ECU to be replaced is still responsive 6. ECU Replacement Without Value Transfer - if the ECU to be replaced is NOT responsive 7. Fuel Mean Value Adaptation Initialization 8. IMA Rapid Calibration Test 9. Set Oil Dilution Mass Value If a CM849 PCM/ECM (5.9L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped If a CM2100 PCM/ECM (6.7l) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Enable / Disable Vehicle Features - need to enable features 4. Injector Quantity Adjustment 5. Reset Regenerative Filter Timers 6. Mobile DeSoot - NO Minimum Required Soot Load If an Asian TCM was replaced, perform the following additional steps and/or routines: If an EATX TCM was replaced, perform the following additional steps and/or routines: If an NGC3 TCM ONLY was replaced, perform the following additional steps and/or routines: If an NGC4 TCM ONLY was replaced, perform the following additional steps and/or routines: 1. Quicklearn If an EGS TCM was replaced, perform the following additional steps and/or routines: 1. Initialize EGS STEP-BY-STEP INSTRUCTIONS Check PCM/ECM VIN Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2342 From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Check PCM/ECM VIN" and follow the on screen instructions. - When complete, select "Finish" Diesel Particulate Filter (Used) Learning From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Diesel Particulate Filter (Used) Learning" and follow the on screen instructions. - When complete, select "Finish" ECU Replacement with Value Transfer From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "ECU Replacement with Value Transfer" and follow the on screen instructions. - When complete, select "Finish" ECU Replacement without Value Transfer From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "ECU Replacement without Value Transfer" and follow the on screen instructions. - When complete, select "Finish" Enable / Disable Vehicle Features From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Enable / Disable Vehicle Features" and follow the on screen instructions. - When complete, select "Finish" Exhaust Throttle Plate Adaptive Learn Position From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Exhaust Throttle Plate Adaptive Learn Position" and follow the on screen instructions. - When complete, select "Finish" Fuel Mean Value Adaptation Initialization From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Fuel Mean Value Adaptation Initialization" and follow the on screen instructions. - When complete, select "Finish" IMA Rapid Calibration From the "Home" screen, select "ECU View" Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2343 - Select "PCM/ECM" - Select "Misc. Functions" - Select "IMA Rapid Calibration Test" and follow the on screen instructions. - When complete, select "Finish" Initialize EGS From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Initialize EGS" and follow the on screen instructions. - When complete, select "Finish" Injector Quantity Adjustment From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Injector Quantity Adjustment" and follow the on screen instructions. - When complete, select "Finish" Mobile DeSoot - NO Minimum Required Soot Load From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Mobile DeSoot - NO Minimum Required Soot Load" and follow the on screen instructions. - When complete, select "Finish" NOx Catalyst (New) Initialization From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "NOx Catalyst (New) Initialization" and follow the on screen instructions. - When complete, select "Finish" PCM/ECM Replaced The vehicle pin (Personal Identification Number) will be required to complete the routine. This information may be obtained in three ways: 1. The original selling invoice 2. DealerCONNECT > Parts > Key Codes 3. Contacting the District Manager. From the "Home" screen, select "ECU View" - Select "WIN" - Select "Misc. Functions" - Select "PCM/ECM Replaced" and follow the on screen instructions. - When complete, select "Finish" Program Variant Code From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Program Variant Code" and follow the on screen instructions. - When complete, select "Finish" Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2344 Quicklearn From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Quicklearn" and follow the on screen instructions. - When complete, select "Finish" Reset Regenerative Filter Timers From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Reset Regenerative Filter Times" and follow the on screen instructions. - When complete, select "Finish" Set Oil Dilution Mass Value From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Set Oil Dilution Mass Value" and follow the on screen instructions. - When complete, select "Finish" SECTION 3 - AUTHORIZED MODIFICATION LABEL NOTE: The following step is required by law when reprogramming a PCM/ECM and/or TCM. Type the necessary information on the "Authorized Modification Label" and attach near the VECI label. 1. Powertrain Control / Transmission Control Module Part Numbers (Insert P/Ns) Used 2. Change Authority: TSB XX--XX 3. Dealer Code: XXXXX 4. Date: XX-XX-XX REQUIRED TOOLS/EQUIPMENT: TECH TIPS and INFORMATION: CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2345 1. The wiTECH(TM) Diagnostic Application is the preferred method for flashing any Chrysler vehicle ECU. For more information, training tutorials are available under the "HELP" tab in the wiTECH(TM) Diagnostic Application, under the 'Training Aids' link. 2. To use the StarMOBILE(R) in Pass-Through Mode requires that your StarMOBILE(R) is connected to the dealerships network via a wired or wireless connection. For more information on how to use the StarMOBILE in Pass-Through Mode see the StarMOBILE(R) training tutorials available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Training Aids' link, under the 'Training Aids' link. 3. If the flash process is interrupted or aborted, the flash should be restarted. 4. Due to the PCM/ECM / TCM programming procedure, a DTC may be set in other ECUs within the vehicle. Some DTCs may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 5. Do not allow the battery charger to time out or the charging rate to climb above 13.5 Volts during the flash process. 6. The StarSCAN(R) and StarMOBILE(R) diagnostic tools fully support Internet connectivity and must be configured for your dealership's network. For help on setting up your StarSCAN(R) / StarMOBILE(R) for the dealership's network, refer to the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the download center. 7. The operating software in the StarSCAN(R) and StarMOBILE(R) must be programmed with the latest software release level. The software level is visible in the blue header at the top of the StarSCAN(R) and StarMOBILE(R) Desktop Client screens. For instructions on how to update your scan tool, refer to the StarSCAN(R) / StarMOBILE(R) Software Update guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the download center. PARTS REQUIRED Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2346 The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2347 If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2348 Engine Control Module: Removal and Replacement Powertrain Control Module - Removal REMOVAL USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. To avoid possible voltage spike damage to PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable. 2. Unlock and disconnect the electrical connectors from PCM. 3. Remove the air cleaner box. 4. Remove the three mounting bolts. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2349 5. Tip module out and remove from bracket. Powertrain Control Module - Installation INSTALLATION USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Tip module into bracket. 2. Install three mounting bolts and tighten to 9 Nm (80 in. lbs.) torque. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2350 3. Check pins in electrical connectors for damage. Repair as necessary. 4. Connect electrical connectors and lock. 5. Install air cleaner box. 6. Connect negative battery cable. 7. Use the scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Main Relay is located in the Fuse/Relay block. Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2354 Main Relay (Computer/Fuel System): Diagrams Connector - (IN F/RB) RELAY-MAIN - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Main Relay is located in the Fuse/Relay block. Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2359 Main Relay (Computer/Fuel System): Diagrams Connector - (IN F/RB) RELAY-MAIN - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2365 Accelerator Pedal Position Sensor: Diagrams Connector - (BODY) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1/1 (Powertrain) 3 Way Camshaft Position Sensor: Diagrams Camshaft Position Sensor 1/1 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CAMSHAFT 1/1 POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1/1 (Powertrain) 3 Way > Page 2371 Camshaft Position Sensor: Diagrams Camshaft Position Sensor 1/2 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CAMSHAFT 1/2 POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Description DESCRIPTION The camshaft position sensors are mounted to the front and rear of the cylinder head. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description > Page 2374 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Operation OPERATION NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt output reference circuit. A ground for the sensor is provided through the sensor return circuit. The PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the camshaft position sensor. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal Front FRONT 1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor electrical connector. 2. Disconnect negative battery cable. 3. Disconnect electrical connector from camshaft position sensor. 4. Remove camshaft position sensor mounting screws. 5. Remove sensor. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 2377 1. Disconnect negative battery cable. 2. Disconnect electrical connector at sensor. 3. Remove nut retaining heat shield. 4. Pull heat shield out to uncover sensor. 5. Remove mounting bolt. 6. Remove sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 2378 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation Front FRONT 1. Lubricate sensor o-ring. 2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9 Nm (79.5 in. lbs.). 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install the negative battery cable. 5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical connector. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 2379 1. Lubricate sensor o-ring. 2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. 3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Carefully attach electrical connector to camshaft position sensor. Feel for positive lock (click). Installation at angle may damage the sensor pins. 5. Install heat shield onto mounting stud. 6. Install heat shield retaining nut and tighten. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 > Page 2384 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor 2 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 > Page 2385 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way > Page 2388 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 2 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 2 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2389 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. ENGINE COOLANT TEMPERATURE SENSOR WIRING OR CONNECTORS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2390 NOTE: Diagnose and repair any ECT circuit DTCs before proceeding with this test. NOTE: Allow the engine to cool to ambient temperature before proceeding. 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature sensor(s) and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Turn the ignition on. 5. Monitor the scan tool data relative to the sensor(s) and wiggle test the wiring and connectors. 6. Look for the data to change or for a DTC to set during the wiggle test. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. ENGINE COOLANT LEVEL AND CONDITION WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Check the engine coolant level and the condition of the engine coolant. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. THERMOSTAT WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Using the appropriate service information, determine the proper opening temperature of the thermostat. 2. With the scan tool, read the Engine Coolant Temperature Sensor value for each sensor. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 3. Monitor the sensor values on the scan tool. 4. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: Each thermostat should open at the temperature specified. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2391 Procedures/Verification Tests/PCM Verification Test No - Go to 4 4. ENGINE COOLANT TEMPERATURE SENSOR NOTE: Allow the engine to cool to ambient temperature before proceeding. WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. With the scan tool, read the Engine Coolant Temperature Sensor value for each sensor. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 2. Monitor each sensor value on the scan tool and the actual coolant temperature with a thermometer. 3. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The sensor value transition should be smooth as the engine reaches operating temperature. The thermometer reading and the coolant temperature values on the scan tool should remain relatively close. Were any problems found? Yes - Go to 5. No - Test complete. 5. ECT SIGNAL CIRCUIT HIGH RESISTANCE NOTE: Perform this procedure for the sensor where erratic sensor values were detected in the previous test step. 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the ECT Signal circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 No - Repair the ECT Signal circuit for excessive resistance. - Perform the PCM Verification Test.See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2392 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the Sensor Ground circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test.See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. ENGINE COOLANT TEMPERATURE SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Engine Coolant Temperature Sensor. - Perform the PCM Verification Test.See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CRANKSHAFT POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The crankshaft position sensor mounts to the rear of the engine block near the transmission. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 2398 Crankshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor (2). The PCM determines which cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth and notches (1), including one long reference tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal REMOVAL The Crankshaft Position Sensor is in the rear of the engine block near the transmission. 1. Remove the engine cover (1). 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner body (1) See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 2401 4. Disengage the upstream O2 sensor wire harness retainer (1) and crankshaft position sensor wire harness retainer (2) from the heat shield (3). 5. Remove one nut (1) and two heat shield retaining bolts (2). 6. Remove heat shield (3). 7. Remove the crankshaft position sensor mounting bolt. 8. Remove sensor with the wire harness attached. 9. Unlock and disconnect the electrical connector from the crankshaft position sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 2402 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation INSTALLATION 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Using a twisting motion, install the crankshaft position sensor. 3. Install the crankshaft position sensor bolt. Tighten the bolt to 9 Nm (80 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 2403 5. Install the heat shield (3) with one nut (1) and two heat shield retaining bolts (2). 6. Install the upstream O2 sensor wire harness retainer (1) and crankshaft position sensor wire harness retainer (2) to the heat shield (3). 7. Install the air cleaner body (1) See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation 8. Connect the negative battery cable. 9. Install the engine cover (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Remove engine cover. 2. Disconnect and isolate negative batter cable. 3. Disconnect upstream DPF temperature sensor electrical connector. 4. Remove upstream DPF temperature sensor. 5. Disconnect downstream DPF temperature sensor electrical connector. 6. Remove downstream DPF temperature sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 2408 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Position DPF downstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 2. Connect downstream temperature sensor electrical connector. 3. Position DPF upstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 4. Connect upstream temperature sensor electrical connector. 5. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Sensor: Service and Repair Removal EXHAUST PRESSURE SENSOR 1. Disconnect and isolate negative battery cable. 2. Remove electrical connector at pressure differential sensor (2). 3. Remove upstream exhaust pressure tube (4) from catalytic converter 4. Remove downstream pressure tube (6) from catalytic converter. 5. Remove pressure differential sensor mounting bolt. 6. Remove pressure differential sensor (2) and tubing (7) from vehicle. 7. Remove tubing (7) from pressure differential sensor (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal > Page 2413 Exhaust Pressure Sensor: Service and Repair Installation EXHAUST PRESSURE SENSOR 1. Install tubing (7) on pressure differential sensor (2). 2. Position pressure differential sensor (2) and tubing (7). 3. Install pressure differential sensor mounting bolt (3). Tighten to 10 Nm (89 in. lbs.). 4. Install downstream pressure tube (6) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.). 5. Install upstream pressure tube (4) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.) 6. Position electrical connector (1) into bracket. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2417 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way Fuel Level Sensor: Diagrams Fuel Pump Module (FWD) (Body) 4 Way Connector (FWD) - (BODY) 4 WAY MODULE-FUEL PUMP (FWD) - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way > Page 2420 Fuel Level Sensor: Diagrams Fuel Pump Module C1 (AWD) (Body) 5 Way Connector C1 (AWD) - (BODY) 5 WAY MODULE-FUEL PUMP (AWD) - (BODY) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way > Page 2421 Fuel Level Sensor: Diagrams Fuel Pump Module C2 (AWD) (Body) 2 Way Connector C2 (AWD) - (BODY) 2 WAY MODULE-FUEL PUMP (AWD) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Level Sensor: Description and Operation Fuel Pump Module - Description DESCRIPTION - FUEL PUMP MODULE The fuel pump module is located on the top left side of the fuel tank. The fuel pump module contains the following components: - Mounting flange - Electric fuel pump - Fuel pump reservoir - Inlet strainer - Fuel pressure regulator - Fuel level sending unit - Fuel filter The fuel level sending unit (3) is the only serviceable component of the fuel pump module. If the electric fuel pump, fuel pressure regulator or fuel filter requires service, the fuel pump module must be replaced as an assembly. DESCRIPTION The fuel pump module is installed in the top of the fuel tank. The fuel pump module contains the following: - Electric fuel pump - Fuel pump reservoir Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 2424 - Inlet strainer - Fuel pressure regulator - Fuel gauge sending unit - Fuel supply line connection - Fuel Filter NOTE: The fuel level sending unit is the only serviceable item. If the fuel pump, fuel pressure regulator or fuel filters need service, replace the fuel pump module as an assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 2425 Fuel Level Sensor: Description and Operation Fuel Pump Module - Operation OPERATION - FUEL PUMP MODULE An electric fuel pump is located within the fuel pump module. The electric fuel pump is a positive displacement, immersible pump with a permanent magnet electric motor capable of creating 860 kPa (125 psi) of operating pressure. The fuel pressure regulator limits fuel pressure to 400 kPa (58 psi). The fuel gauge is controlled by the instrument cluster circuit board based upon cluster programming and a hard wired input received by the cluster from the fuel level sending unit on the module in the fuel tank. The instrument cluster continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. This information is available to other vehicle control modules via the Controller Area Network (CAN) data bus. Fuel gauge diagnosis is conducted as part ofthe instrument cluster circuitry. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Level Sensor: Service and Repair Fuel Pump Module - Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. 1. Perform Fuel System Pressure Release procedure. See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair 2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose. 3. Remove the negative battery cable. 4. Remove the rear seat cushion. 5. Rear seat cushion loose. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2428 6. Remove plastic cover. 7. Clean top of tank to remove loose dirt and debris. 8. Use special tool #9340 to remove left side module lock ring. 9. Note the fuel pump location on the top of the fuel tank. NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2429 10. Pull module up out of fuel tank, make sure that you do not spill fuel inside of vehicle. 11. Drain fuel from fuel pump module. Do not spill fuel in interior of vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2430 Fuel Level Sensor: Service and Repair Fuel Pump Module - Installation INSTALLATION NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. 1. Wipe seal area of tank clean. Place a new seal between the tank threads and the pump module opening. 2. Install module. 3. Position fuel pump module in tank. Make sure the alignment tab lines up on the fuel tank and pump module for Gas or Diesel fuel tanks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2431 4. While holding the pump module in position, install lock ring and use special tool Spanner Wrench #9340 to tighten lock ring. 5. Install plastic cover. 6. Install rear cushion. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2432 7. Install the negative battery cable. 8. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. 9. Fill fuel tank with clean fuel. Use the Scan Tool to pressurize the system and check for leaks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2436 Intake Air Temperature Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-INTAKE AIR TEMPERATURE (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect electrical connector from sensor. 3. Remove the sensor clean air duct. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 2439 Intake Air Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install inlet air temperature sensor into the clean air duct. 2. Connect electrical connector to sensor. 3. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2443 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2444 Knock Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-KNOCK (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal REMOVAL The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Disconnect the negative battery cable. 2. Remove the bolt holding the knock sensor. 3. Remove sensor with electrical connector attached. 4. Disconnect electrical connector from knock sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 2447 5. Remove the knock sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 2448 Knock Sensor: Service and Repair Knock Sensor - Installation INSTALLATION The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Attach electrical connector to knock sensor. 2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening effects knock sensor performance, possibly causing improper spark control. 3. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2452 Manifold Pressure/Vacuum Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-MAP (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Operation Manifold Pressure/Vacuum Sensor: Description and Operation Operation OPERATION The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 volt and full scale is 4.5 volt. For a pressure swing of 0 - 15 psi the voltage changes 4.0 volt. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key on. The difference between current and what it was at key on is manifold vacuum. During key On (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in your work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC1 transmissions only, via the PCI bus) - Idle speed - Decel fuel shutoff The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 88 kPa (26 in. Hg). Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 101 kPa (29.92 in. Hg). For every 30.5 meters (100 feet) of altitude barometric pressure drops.33 kPa (0.10 in. Hg). If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Operation > Page 2455 Manifold Pressure/Vacuum Sensor: Description and Operation Description DESCRIPTION The MAP sensor mounts to the intake manifold. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Page 2456 Manifold Pressure/Vacuum Sensor: Testing and Inspection CHECKING THE MAP SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. MAP SENSOR WIRING OR CONNECTORS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Page 2457 NOTE: Diagnose and repair any MAP Sensor circuit DTCs before proceeding with this test. NOTE: Diagnose and repair any sensor supply or system voltage DTCs before proceeding with this test. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. MAP VACUUM/BAROMETRIC PRESSURE 1. With a scan tool, read the Barometric Pressure. NOTE: The Barometric Pressure should be approximately equal to the actual barometric pressure. If necessary, compare the Barometric Pressure value of the tested vehicle to the value of a known good vehicle of a similar make and model. 2. Connect a vacuum gauge to a manifold vacuum source. 3. Start the engine. NOTE: If engine will not idle, maintain a constant RPM above idle. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 4. With the scan tool, read the MAP Sensor vacuum. NOTE: The scan tool reading for MAP vacuum should be within 1" of the vacuum gauge reading. Were any problems found? Yes - Go to 4 No - Go to 3 3. MAP SENSOR VOLTAGE 1. With the scan tool, monitor the MAP Sensor signal voltage. 2. With the engine idling in neutral or park, snap the throttle. NOTE: The MAP Sensor signal voltage should change from below 2.0 volts at idle to above 3.5 volts at wide open throttle. Were any problems found? Yes - Go to 4 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Page 2458 No - Test complete. 4. (F856) 5 VOLT SUPPLY CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (F856) 5 Volt Supply circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 5 No - Repair the (F856) 5 Volt Supply circuit for excessive resistance. - Perform the PCM Verification Test.See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 5. (K1) MAP SIGNAL CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K1) MAP Signal circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 No - Repair the (K1) MAP Signal circuit for excessive resistance. - Perform the PCM Verification Test.See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the MAP Sensor harness connector and by Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Page 2459 probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the (K900) Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test.See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. MAP SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the MAP Sensor. - Perform the PCM Verification Test.See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect electrical connector from manifold absolute pressure (MAP) sensor. 3. Remove screw from MAP sensor. 4. Remove MAP sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 2462 Manifold Pressure/Vacuum Sensor: Service and Repair Installation INSTALLATION 1. Install manifold absolute pressure (MAP) sensor to intake manifold. 2. Tighten screw to 4.5 Nm (40 in. lbs.). 3. Connect electrical connector to sensor. 4. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 2467 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Powertrain) 4 Way Oxygen Sensor: Diagrams Oxygen Sensor 1/1 (Powertrain) 4 Way Connector (GAS) - (POWERTRAIN) 4 WAY SENSOR-OXYGEN 1/1 (GAS) - (POWERTRAIN) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Powertrain) 4 Way > Page 2470 Oxygen Sensor: Diagrams Oxygen Sensor 1/2 (Engine Compartment) 4 Way Connector (GAS) - (ENGINE COMPARTMENT) 4 WAY SENSOR-OXYGEN 1/2 (GAS) - (ENGINE COMPARTMENT) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2471 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Oxygen Sensor: Description and Operation Description DESCRIPTION The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. The downstream heated oxygen sensor threads into the system depending on emission package. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description > Page 2474 Oxygen Sensor: Description and Operation Operation OPERATION Separate upstream and downstream grounds are used on the NGC vehicles (4 Cyl.). As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The O2 sensors produce a constant 2.5 volts on NGC vehicles, depending upon the oxygen content of the exhaust gas. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produce a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, which can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2 sensor's input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The NGC Controller has a common ground for the heater in the O2S. 12 volts is supplied to the heater in the O2S by the NGC controller. Both the upstream and downstream O2 sensors for NGC are pulse width modulation (PWM). NOTE: When replacing an O2 Sensor, the PCM RAM memory must be cleared, either by disconnecting the PCM C-1 connector or momentarily disconnecting the Battery negative terminal. The NGC learns the characteristics of each O2 heater element and these old values should be cleared when installing a new O2 sensor. The customer may experience driveability issues if this is not performed. UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 2.5 to 3.5 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 2.5 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 3.5 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. This is also used to establish the upstream O2 goal voltage (switching point). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 2475 Oxygen Sensor: Testing and Inspection CHECKING THE OXYGEN SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. OXYGEN SENSOR, WIRING OR CONNECTORS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 2476 NOTE: Diagnose and repair any O2 sensor or rationality DTCs before proceeding with this test. NOTE: When performing this procedure as part of another diagnostic process, it may be necessary to repeat this test for all of the oxygen sensors on the vehicle. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen sensor and the Powertrain Control Module (PCM). 3. Look for any chafed, pierced, pinched or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. OXYGEN SENSOR VOLTAGE 1. Start the engine and allow it to reach normal operating temperature. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 2. With a scan tool, monitor all O2 Sensor voltage readings. Is the voltage switching between 2.5 and 3.4 volts for all O2 sensors? Yes - Go To 3 No - Go To 4 3. O2 SENSOR HEATER OPERATION 1. Turn the ignition off. NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0 volts. 2. Turn the ignition on. 3. With a scan tool, actuate the O2 Sensor heater. 4. With the scan tool, monitor O2 Sensor voltage for at least two minutes. Does the voltage stay above 4.5 volts? Yes - Go To 4 No - Test complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 2477 4. O2 SENSOR 1. Turn the ignition off. NOTE: Check for contaminants that may cause improper O2 Sensor operation, such as contaminated fuel, unapproved silicone, or evidence of oil or coolant. 2. Disconnect the O2 Sensor harness connector. 3. Turn the ignition on. 4. With a scan tool, monitor the O2 Sensor voltage. NOTE: The voltage should be approximately 5.0 volts with the connector disconnected. 5. Connect a jumper wire between the signal circuit and the return circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from 5.0 volts to 2.5 volts with the jumper wire in place. Is the O2 Sensor voltage displayed on the scan tool as described? Yes - Replace the O2 Sensor. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 5 5. O2 SENSOR SIGNAL CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Signal circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor signal circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 6 6. O2 SENSOR RETURN CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Return circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor return circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 7 7. POWERTRAIN CONTROL MODULE (PCM) 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the O2 sensor and the PCM. 2. Look for any chafed, pierced, pinched or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Monitor the scan tool data relative to the components tested in this procedure and wiggle test the wiring and connectors. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 2478 5. Look for the data to change or for a DTC to set during the wiggle test. 6. Search for any Technical Service Bulletins (TSBs) that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Replace and program the Powertrain Control Module (PCM). - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal Oxygen Sensor: Service and Repair Removal 2.4L DOWNSTREAM OXYGEN SENSOR (1/2) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wires going into oxygen sensor. Damage to the oxygen sensor may occur. NOTE: Use an oxygen sensor (O2S) removal tool for this procedure. 1. Raise and support vehicle. 2. Disconnect O2S wire harness mounting clips from engine or body, if equipped. 3. Disconnect O2S pigtail harness connector (1) from engine wiring harness. 4. Remove O2S (3) from exhaust pipe (2). UPSTREAM OXYGEN SENSOR (1/1) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wires going into oxygen sensor. Damage to the oxygen Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 2481 sensor may occur. NOTE: Use an oxygen sensor (O2S) removal tool for this procedure. 1. Raise and support vehicle. 2. Disconnect O2S wire harness mounting clips from engine or body, if equipped. 3. Disconnect O2S pigtail harness connector (1) from engine wiring harness. 4. Remove O2S (3) from maniverter (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 2482 Oxygen Sensor: Service and Repair Installation 2.4L DOWNSTREAM OXYGEN SENSOR (1/2) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted back to their original positions on engine or body to prevent mechanical damage to wiring. NOTE: Use an O2S removal tool for this procedure. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new O2S. 1. Install O2 sensor (3) to exhaust pipe (2). Tighten to 41 Nm (30 ft. lbs.). 2. Connect O2 sensor pigtail harness connector (1) to engine wiring harness. 3. Connect O2S wire harness mounting clips to engine or body, if equipped. UPSTREAM OXYGEN SENSOR (1/1) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 2483 CAUTION: When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted back to their original positions on engine or body to prevent mechanical damage to wiring. NOTE: Use an O2S removal tool for this procedure. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new O2S. 1. Install O2 sensor (3) to maniverter (2). Tighten to 41 Nm (30 ft. lbs.). 2. Connect O2 sensor pigtail harness connector (1) to engine wiring harness. 3. Connect O2S wire harness mounting clips to engine or body, if equipped. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams Vehicle Speed Sensor: Diagrams Connector (GAS MTX) - (POWERTRAIN) 3 WAY SENSOR-VEHICLE SPEED (GAS MTX) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Remove engine cover. 2. Disconnect and isolate negative batter cable. 3. Disconnect upstream DPF temperature sensor electrical connector. 4. Remove upstream DPF temperature sensor. 5. Disconnect downstream DPF temperature sensor electrical connector. 6. Remove downstream DPF temperature sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 2492 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Position DPF downstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 2. Connect downstream temperature sensor electrical connector. 3. Position DPF upstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 4. Connect upstream temperature sensor electrical connector. 5. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2497 Accelerator Pedal Position Sensor: Diagrams Connector - (BODY) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Description and Operation > Oil Pressure Switch - Description Oil Pressure Switch (For Fuel Pump): Description and Operation Oil Pressure Switch - Description DESCRIPTION The oil pressure switch is located on the left front side of the engine block. The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Description and Operation > Oil Pressure Switch - Description > Page 2502 Oil Pressure Switch (For Fuel Pump): Description and Operation Oil Pressure Switch - Operation OPERATION The oil pressure switch is normally "Closed." The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig. The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Raise and support the vehicle See: Maintenance/Vehicle Lifting/Service and Repair 3. Remove the splash shield from the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 4. Remove the accessory drive belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal 5. Remove the three bolts (2) and reposition the A/C compressor (1). 6. Disconnect the oil pressure switch electrical connector. 7. Remove the oil pressure switch using oil pressure socket C-4597 (1) or equivalent. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal > Page 2505 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Installation INSTALLATION NOTE: If the oil pressure switch is removed, it must be replaced with a new switch. CAUTION: The oil pressure switch has tapered threads, over tightening could crack the engine block. 1. Install the oil pressure switch using oil pressure socket C-4597 (1) or equivalent. Tighten switch to 8 Nm (71 in. lbs.). 2. Connect the oil pressure switch electrical connector. 3. Position the A/C compressor (1) and install three mounting bolts (2). Tighten bolts to 25 Nm (18 ft. lbs.). 4. Install the accessory drive belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation 5. Install the splash shield to the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 6. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1/1 (Powertrain) 3 Way Camshaft Position Sensor: Diagrams Camshaft Position Sensor 1/1 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CAMSHAFT 1/1 POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1/1 (Powertrain) 3 Way > Page 2512 Camshaft Position Sensor: Diagrams Camshaft Position Sensor 1/2 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CAMSHAFT 1/2 POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Description DESCRIPTION The camshaft position sensors are mounted to the front and rear of the cylinder head. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description > Page 2515 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Operation OPERATION NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt output reference circuit. A ground for the sensor is provided through the sensor return circuit. The PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the camshaft position sensor. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal Front FRONT 1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor electrical connector. 2. Disconnect negative battery cable. 3. Disconnect electrical connector from camshaft position sensor. 4. Remove camshaft position sensor mounting screws. 5. Remove sensor. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 2518 1. Disconnect negative battery cable. 2. Disconnect electrical connector at sensor. 3. Remove nut retaining heat shield. 4. Pull heat shield out to uncover sensor. 5. Remove mounting bolt. 6. Remove sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 2519 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation Front FRONT 1. Lubricate sensor o-ring. 2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9 Nm (79.5 in. lbs.). 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install the negative battery cable. 5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical connector. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 2520 1. Lubricate sensor o-ring. 2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. 3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Carefully attach electrical connector to camshaft position sensor. Feel for positive lock (click). Installation at angle may damage the sensor pins. 5. Install heat shield onto mounting stud. 6. Install heat shield retaining nut and tighten. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CRANKSHAFT POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The crankshaft position sensor mounts to the rear of the engine block near the transmission. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 2526 Crankshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor (2). The PCM determines which cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth and notches (1), including one long reference tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal REMOVAL The Crankshaft Position Sensor is in the rear of the engine block near the transmission. 1. Remove the engine cover (1). 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner body (1) See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 2529 4. Disengage the upstream O2 sensor wire harness retainer (1) and crankshaft position sensor wire harness retainer (2) from the heat shield (3). 5. Remove one nut (1) and two heat shield retaining bolts (2). 6. Remove heat shield (3). 7. Remove the crankshaft position sensor mounting bolt. 8. Remove sensor with the wire harness attached. 9. Unlock and disconnect the electrical connector from the crankshaft position sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 2530 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation INSTALLATION 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Using a twisting motion, install the crankshaft position sensor. 3. Install the crankshaft position sensor bolt. Tighten the bolt to 9 Nm (80 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 2531 5. Install the heat shield (3) with one nut (1) and two heat shield retaining bolts (2). 6. Install the upstream O2 sensor wire harness retainer (1) and crankshaft position sensor wire harness retainer (2) to the heat shield (3). 7. Install the air cleaner body (1) See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation 8. Connect the negative battery cable. 9. Install the engine cover (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Removal REMOVAL WARNING: Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. This will disable the front airbag system. Failure to disconnect the battery could result in accidental front airbag module deployment and possible personal injury.Do not place a non-deployed airbag face down on a hard surface as the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. 1. Remove air cleaner fresh air duct (2) and disconnect and isolate negative battery cable at battery, See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal. 2. Remove upper (1) and lower (2) steering column shrouds,See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 2537 3. Remove steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 4. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket integral to the right side of the clockspring (3) on the steering column. 5. Slide the switch away from the clockspring far enough to disengage the slide tab on the bottom of the switch housing from the channel formation in the mounting bracket. Position the multi-function switch (1) aside. 6. Position steering column to the full down position. 7. Position ignition key to the RUN position. 8. Remove screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 9. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and position the SKREEM/WCM (2) back on the lock cylinder housing (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 2538 10. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing. Depress the key cylinder retaining tab. 11. Pull key cylinder (3) and key (2) straight out of the lock cylinder housing as one unit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 2539 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Installation INSTALLATION 1. Place actuator in the lock cylinder housing to the RUN position (if not already there). 2. Insert key into key cylinder and turn key cylinder to the RUN position. 3. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 4. Slide key cylinder into the lock cylinder housing until key cylinder retaining tab locks the cylinder into place. 5. Rotate key back and forth (OFF to START), then remove and reinstall it, making sure key cylinder and lock cylinder housing operate properly. 6. Slide the ring of SKREEM/WCM (2) over lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 7. Install screw (1) fastening the SKREEM/WCM (2) to lock cylinder housing (3). Tighten screw to 2.5 Nm (22 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 2540 8. Install and tighten the screw (2) that secures the mounting tab on the back of the right multi-function switch (1) to the mounting bracket on the clockspring (3). 9. Install steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 10. Install upper (1) and lower (2) steering column shrouds,See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 2541 11. Install air cleaner fresh air duct (2) and disconnect and isolate negative battery cable at battery, See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Installation. 12. Check operation of all steering column mounted components. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2545 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2546 Knock Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-KNOCK (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal REMOVAL The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Disconnect the negative battery cable. 2. Remove the bolt holding the knock sensor. 3. Remove sensor with electrical connector attached. 4. Disconnect electrical connector from knock sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 2549 5. Remove the knock sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 2550 Knock Sensor: Service and Repair Knock Sensor - Installation INSTALLATION The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Attach electrical connector to knock sensor. 2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening effects knock sensor performance, possibly causing improper spark control. 3. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System Fuel Pressure: Testing and Inspection Checking the Fuel Delivery System CHECKING THE FUEL DELIVERY SYSTEM For a complete wiring diagram, refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. CHECKING THE FUEL PUMP OPERATION 1. Turn the ignition on. NOTE: Diagnose and repair any fuel pump control circuit or relay DTCs before continuing with this test. 2. With a scan tool, actuate the fuel pump control to ON (100%). NOTE: It may be necessary to use a mechanics stethoscope in the next step. 3. Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly, without excessive noise. If necessary, compare to a known good vehicle of similar year, make, and model. NOTE: If the pump has excessive noise or grinding, the pump should be replaced. CAUTION: Stop all actuation tests before continuing. Is the fuel pump operating when actuated? Yes - Go To 2 No - Go To 7 2. CHECKING THE FUEL PRESSURE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Install a fuel pressure gauge on the fuel rail. 3. Turn the ignition on. 4. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: Non SRT fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). CAUTION: Stop all actuation tests before continuing. Select the conclusion that best matches the result of the test: Fuel pressure is within the stated specification - Test complete. Fuel pressure is below the stated specification - Go To 3 Fuel pressure is above the stated specification - Replace the fuel filter/pressure regulator. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 3. RESTRICTED FUEL SUPPLY LINE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2557 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. 3. Install special 5/16 fuel line adapter tool #6539 between disconnected fuel line and the fuel pump module. 4. Attach a fuel pressure test gauge to the T fitting on tool #6539. 5. Turn the ignition on. 6. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: Non SRT fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). CAUTION: Stop all actuation tests before proceeding. Is the fuel pressure within specification? Yes - Repair or replace fuel supply line as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 4 4. SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes - Go To 5 No - Go To 6 5. FUEL TANK SIPHON HOSE OR FUEL LINE RESTRICTED OR DAMAGED 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Gain access to the fuel pump module and the fuel tank module. 3. Inspect the fuel line and siphon hose between the fuel pump module and the fuel tank module. Look for disconnected or damaged lines and hoses. 4. Inspect the fuel pressure regulator for damage or a condition that might cause a fuel flow problem. Make sure that it is seated in the module properly. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 6 6. FUEL PUMP INLET STRAINER 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2558 WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Remove the fuel pump module and inspect the fuel inlet strainer for damage or a condition that might cause a fuel flow problem. Were any problems found? Yes - Replace the Fuel Pump Inlet Strainer. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. 7. FUEL PUMP GROUND CIRCUIT OPEN OR HIGH RESISTANCE 1. Turn the ignition off. 2. Disconnect the Fuel Pump Module harness connector. 3. Using a 12-volt test light connected to 12 volts, check the Fuel Pump Motor Ground circuit at the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Repair the Fuel Pump Ground circuit for an open circuit or high resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2559 Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down FUEL PRESSURE LEAK DOWN For a complete wiring diagram, refer to the Wiring Information. See: Diagrams/Electrical Diagrams WARNING: Follow these safety precautions to reduce the risk of fire and serious possible serious or fatal injury when performing this test procedure. Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. Use extreme caution when connecting and disconnecting fuel lines. - Considerable fuel leakage may occur when servicing the fuel system. Wear protective eye wear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair / replace as necessary. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2560 WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from Gas and Diesel Fuel Pressure/Decay Tester 8978. Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly Fuel Inlet Hose 8978-1 (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect the Reservoir Assembly 534960 (4) to the Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 2561 - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 2. Turn the ignition on, wait five seconds, turn the ignition off and then wait 1 minute before proceeding. 3. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT-4 fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the Checking The Fuel Delivery System diagnostic procedure as directed. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System 5. CHECK FUEL DELIVERY SYSTEM FOR LEAK DOWN WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Close the Fuel System Isolation Valve (1) and then wait five minutes before proceeding. 2. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge (1) - Replace the fuel pump module. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Yes - On Fuel Outlet Gauge (2) - Replace the leaking fuel injector(s). - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - If directed here by another test, return to that test. Otherwise, test complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal Air Filter Element: Service and Repair Air Cleaner - Removal REMOVAL 1. Turn lock retainers (5) and remove fresh air inlet (2) from air cleaner housing (1). 2. Disconnect intake air temperature sensor connector (4). 3. Remove air inlet tube (5) from air cleaner housing (1). 4. Unfasten clasps (2) on sides of air cleaner housing cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 2567 5. Pull air cleaner cover (1) aside. 6. Remove filter element (3). 7. If necessary, clean the inside of the air cleaner housing (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 2568 Air Filter Element: Service and Repair Air Cleaner - Installation INSTALLATION 1. Install new filter element. 2. Place cover over air cleaner housing. Snap clasps (2) in place. 3. Install air inlet tube (5). 4. Connect intake air temperature sensor connector (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 2569 5. Install fresh air inlet (2) on air cleaner housing (1) and lock retainers (5). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove lower rear seat cushion. 2. Remove the fuel pump module cover. 3. Disconnect the electrical connector for fuel pump module. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. Turn ignition key to OFF position. 7. Disconnect negative battery cable. 8. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory. The scan tool must be used to erase a DTC. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications FIRING ORDER 1.8, 2.0, 2.4L The firing order is 1-3-4-2. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications Spark Plug: Specifications Spark Plug Specifications SPARK PLUGS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications > Page 2581 Spark Plug: Specifications Torque SPARK PLUG Spark Plugs.......................................................................................................................................... ........................................................27 Nm (20 ft. lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2582 Spark Plug: Application and ID Spark Plug Type................................................................................................................................... ....................................................................ZFR5F-11 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal Spark Plug: Service and Repair Spark Plug - Removal REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the electrical connectors from ignition coils. 3. Remove the ignition coil mounting bolt. 4. Twist the ignition coil then pull straight up. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 2585 5. Remove the spark plug using a quality socket with a rubber or foam insert. 6. Inspect the spark plug condition. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 2586 Spark Plug: Service and Repair Spark Plug - Installation INSTALLATION CAUTION: Handle the spark plugs with care. Do not drop or force the spark plugs into the wells, damage to the electrodes and/or porcelain body may occur. Always start each spark plug by hand in order to avoid cross-threading the spark plug in the cylinder head. Always tighten spark plugs to the specified torque. Too much or not enough torque will cause damage to the cylinder head and/or spark plug and may lead to poor engine performance. 1. Install each spark plug to the cylinder head. Tighten spark plugs to 27 Nm (20 ft. lbs.). 2. Install ignition coil onto spark plug. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 2587 3. Install ignition coil mounting bolt. Tighten to 9 Nm (79.5 in. lbs.). 4. Connect ignition coil electrical connectors. 5. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications COMPRESSION CHECK Compression Pressure ............................................................................................................................................................. 1172-1551 kPa (170-225 psi) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2591 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove engine cover. 4. Disconnect coil electrical connectors and remove coils. 5. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators such as fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 6. Disconnect injector electrical connectors. 7. Insert compression gauge adaptor 8116 or the equivalent, into the #1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer CH7059 with cable adaptors to the DRBIII(R). For Special Tool identification, . See: Engine, Cooling and Exhaust/Engine/Tools and Equipment 8. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder pressure. 9. Repeat the previous step for all remaining cylinders. 10. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 11. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 12. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Lash Intake.................................................................................................................................................... ..............................0.17 - 0.23 mm (0.006 - 0.009 in.) Exhaust............................................................ ...................................................................................................................0.27 - 0.33 mm (0.010 0.012 in.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2595 Valve Clearance: Adjustments MEASURING VALVE LASH NOTE: The engine must be cold to measure valve lash. 1. Remove engine cover. 2. Remove cylinder head coverSee: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal. 3. Rotate camshaft so lobes are vertical (1). 4. Check clearance using feeler gauges. 5. Repeat for all tappets and record readings. 6. If clearance was too small, refer to the Clearance too Small procedure. Clearance too Small. 7. If clearance was too large, refer to the Clearance too Large procedure. Clearance too Large. Clearance too Small Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2596 1. Remove camshaftsSee: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Removal. 2. Specification - clearance = change. 3. Decrease tappet thickness by change figure. 4. Install camshafts See: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Installation. 5. Verify that valve lash is correct. Clearance too Large 1. Remove camshaftsSee: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Removal. 2. Clearance - specification = change. 3. Increase tappet thickness by change figure. 4. Install camshaftsSee: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Removal and Replacement/Camshaft - Installation. 5. Verify that valve lash is correct. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2601 Accelerator Pedal Position Sensor: Diagrams Connector - (BODY) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2605 Intake Air Temperature Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-INTAKE AIR TEMPERATURE (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect electrical connector from sensor. 3. Remove the sensor clean air duct. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 2608 Intake Air Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install inlet air temperature sensor into the clean air duct. 2. Connect electrical connector to sensor. 3. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1/1 (Powertrain) 3 Way Camshaft Position Sensor: Diagrams Camshaft Position Sensor 1/1 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CAMSHAFT 1/1 POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1/1 (Powertrain) 3 Way > Page 2614 Camshaft Position Sensor: Diagrams Camshaft Position Sensor 1/2 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CAMSHAFT 1/2 POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Description DESCRIPTION The camshaft position sensors are mounted to the front and rear of the cylinder head. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description > Page 2617 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Operation OPERATION NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt output reference circuit. A ground for the sensor is provided through the sensor return circuit. The PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the camshaft position sensor. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal Front FRONT 1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor electrical connector. 2. Disconnect negative battery cable. 3. Disconnect electrical connector from camshaft position sensor. 4. Remove camshaft position sensor mounting screws. 5. Remove sensor. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 2620 1. Disconnect negative battery cable. 2. Disconnect electrical connector at sensor. 3. Remove nut retaining heat shield. 4. Pull heat shield out to uncover sensor. 5. Remove mounting bolt. 6. Remove sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 2621 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation Front FRONT 1. Lubricate sensor o-ring. 2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9 Nm (79.5 in. lbs.). 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install the negative battery cable. 5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical connector. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 2622 1. Lubricate sensor o-ring. 2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. 3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Carefully attach electrical connector to camshaft position sensor. Feel for positive lock (click). Installation at angle may damage the sensor pins. 5. Install heat shield onto mounting stud. 6. Install heat shield retaining nut and tighten. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Remove engine cover. 2. Disconnect and isolate negative batter cable. 3. Disconnect upstream DPF temperature sensor electrical connector. 4. Remove upstream DPF temperature sensor. 5. Disconnect downstream DPF temperature sensor electrical connector. 6. Remove downstream DPF temperature sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 2627 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Position DPF downstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 2. Connect downstream temperature sensor electrical connector. 3. Position DPF upstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 4. Connect upstream temperature sensor electrical connector. 5. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 > Page 2632 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor 2 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 > Page 2633 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way > Page 2636 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 2 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 2 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2637 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. ENGINE COOLANT TEMPERATURE SENSOR WIRING OR CONNECTORS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2638 NOTE: Diagnose and repair any ECT circuit DTCs before proceeding with this test. NOTE: Allow the engine to cool to ambient temperature before proceeding. 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature sensor(s) and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Turn the ignition on. 5. Monitor the scan tool data relative to the sensor(s) and wiggle test the wiring and connectors. 6. Look for the data to change or for a DTC to set during the wiggle test. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. ENGINE COOLANT LEVEL AND CONDITION WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Check the engine coolant level and the condition of the engine coolant. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. THERMOSTAT WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Using the appropriate service information, determine the proper opening temperature of the thermostat. 2. With the scan tool, read the Engine Coolant Temperature Sensor value for each sensor. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 3. Monitor the sensor values on the scan tool. 4. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: Each thermostat should open at the temperature specified. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2639 Tests/PCM Verification Test No - Go to 4 4. ENGINE COOLANT TEMPERATURE SENSOR NOTE: Allow the engine to cool to ambient temperature before proceeding. WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. With the scan tool, read the Engine Coolant Temperature Sensor value for each sensor. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 2. Monitor each sensor value on the scan tool and the actual coolant temperature with a thermometer. 3. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The sensor value transition should be smooth as the engine reaches operating temperature. The thermometer reading and the coolant temperature values on the scan tool should remain relatively close. Were any problems found? Yes - Go to 5. No - Test complete. 5. ECT SIGNAL CIRCUIT HIGH RESISTANCE NOTE: Perform this procedure for the sensor where erratic sensor values were detected in the previous test step. 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the ECT Signal circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 No - Repair the ECT Signal circuit for excessive resistance. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 2640 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the Sensor Ground circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. ENGINE COOLANT TEMPERATURE SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Engine Coolant Temperature Sensor. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CRANKSHAFT POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The crankshaft position sensor mounts to the rear of the engine block near the transmission. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 2646 Crankshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor (2). The PCM determines which cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth and notches (1), including one long reference tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal REMOVAL The Crankshaft Position Sensor is in the rear of the engine block near the transmission. 1. Remove the engine cover (1). 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner body (1) See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 2649 4. Disengage the upstream O2 sensor wire harness retainer (1) and crankshaft position sensor wire harness retainer (2) from the heat shield (3). 5. Remove one nut (1) and two heat shield retaining bolts (2). 6. Remove heat shield (3). 7. Remove the crankshaft position sensor mounting bolt. 8. Remove sensor with the wire harness attached. 9. Unlock and disconnect the electrical connector from the crankshaft position sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 2650 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation INSTALLATION 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Using a twisting motion, install the crankshaft position sensor. 3. Install the crankshaft position sensor bolt. Tighten the bolt to 9 Nm (80 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 2651 5. Install the heat shield (3) with one nut (1) and two heat shield retaining bolts (2). 6. Install the upstream O2 sensor wire harness retainer (1) and crankshaft position sensor wire harness retainer (2) to the heat shield (3). 7. Install the air cleaner body (1) See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation 8. Connect the negative battery cable. 9. Install the engine cover (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2655 Data Link Connector: Diagrams Connector - (INSTRUMENT PANEL) 16 WAY DATA LINK CONNECTOR - (INSTRUMENT PANEL) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Data Link Connector - Description Data Link Connector: Description and Operation Data Link Connector - Description DESCRIPTION The Data Link Connector (DLC) (1) is a 16-way molded plastic connector that is part of the instrument panel wire harness. This connector is located at the lower edge of the instrument panel, outboard of the steering column. The connector insulator is retained by integral snap features within a rectangular cutout in a mounting bracket integral to the lower instrument panel and inboard of the inside hood release on the inner cowl side trim. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Data Link Connector - Description > Page 2658 Data Link Connector: Description and Operation Data Link Connector - Operation OPERATION The Data Link Connector (DLC) is an industry-standard 16-way connector that permits the connection of a diagnostic scan tool to the Controller Area Network (CAN) data bus for interfacing with, configuring, and retrieving Diagnostic Trouble Code (DTC) data from the electronic modules that reside on the data bus network of the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2667 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2668 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2669 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2670 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2671 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2672 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2673 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2674 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2675 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2676 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2677 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: Recalls Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P0139/P0571 Set NUMBER: 18-018-09 GROUP: Vehicle Performance DATE: June 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For Diagnostic Trouble Code P0139 Or P0571 Is Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey 2009 (JS) Sebring/Avenger/Sebring Convertible 2009 (PM) Caliber 2009 (MK) Compass/Patriot NOTE: This bulletin applies to: - 2009 JS vehicles equipped with a 2.0L/2.4L Engine (Sales Code ECN or EDG or ED3) built before July 27, 2009 (MDH 0727XX) - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before July 27, 2009 (MDH 0727XX) - 2009 PM/MK vehicles equipped with a 1.8L, 2.0L or 2.4L engines (Sales Codes EBA, ECN and ED3) built before July 10, 2009 (MDH 0710XX) SYMPTOM/CONDITION: Some customers may experience a MIL illumination. The MIL is for P0139 - 02 Sensor 1/2 Slow Response. Further investigation by the technician may also find DTC P0571. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other then the ones listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set > Page 2687 If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0139/P0571 Set NUMBER: 18-018-09 GROUP: Vehicle Performance DATE: June 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For Diagnostic Trouble Code P0139 Or P0571 Is Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey 2009 (JS) Sebring/Avenger/Sebring Convertible 2009 (PM) Caliber 2009 (MK) Compass/Patriot NOTE: This bulletin applies to: - 2009 JS vehicles equipped with a 2.0L/2.4L Engine (Sales Code ECN or EDG or ED3) built before July 27, 2009 (MDH 0727XX) - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before July 27, 2009 (MDH 0727XX) - 2009 PM/MK vehicles equipped with a 1.8L, 2.0L or 2.4L engines (Sales Codes EBA, ECN and ED3) built before July 10, 2009 (MDH 0710XX) SYMPTOM/CONDITION: Some customers may experience a MIL illumination. The MIL is for P0139 - 02 Sensor 1/2 Slow Response. Further investigation by the technician may also find DTC P0571. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other then the ones listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set > Page 2693 If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2698 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2699 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2700 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2701 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2702 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2703 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2704 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2705 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2706 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2707 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2708 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: All Technical Service Bulletins Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0139/P0571 Set NUMBER: 18-018-09 GROUP: Vehicle Performance DATE: June 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For Diagnostic Trouble Code P0139 Or P0571 Is Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey 2009 (JS) Sebring/Avenger/Sebring Convertible 2009 (PM) Caliber 2009 (MK) Compass/Patriot NOTE: This bulletin applies to: - 2009 JS vehicles equipped with a 2.0L/2.4L Engine (Sales Code ECN or EDG or ED3) built before July 27, 2009 (MDH 0727XX) - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before July 27, 2009 (MDH 0727XX) - 2009 PM/MK vehicles equipped with a 1.8L, 2.0L or 2.4L engines (Sales Codes EBA, ECN and ED3) built before July 10, 2009 (MDH 0710XX) SYMPTOM/CONDITION: Some customers may experience a MIL illumination. The MIL is for P0139 - 02 Sensor 1/2 Slow Response. Further investigation by the technician may also find DTC P0571. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other then the ones listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set > Page 2718 If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2724 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2725 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2726 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2727 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2728 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2729 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2730 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2731 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2732 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2733 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2734 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: All Technical Service Bulletins Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2739 Engine Control Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2740 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way Engine Control Module: Diagrams Powertrain Control Module C1 (Engine Compartment) 58 Way Connector C1 (GAS) - (ENGINE COMPARTMENT) 58 WAY MODULE-POWERTRAIN CONTROL (GAS) - (ENGINE COMPARTMENT) 58 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2743 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2744 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2745 Engine Control Module: Diagrams Powertrain Control Module C2 (Engine Compartment) 96 Way Connector C2 (GAS) - (ENGINE COMPARTMENT) 96 WAY MODULE-POWERTRAIN CONTROL (GAS) - (ENGINE COMPARTMENT) 96 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2746 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2747 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2748 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description Engine Control Module: Description and Operation Powertrain Control Module - Description Sensor Return - PCM Input SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). PCM Ground PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded separately from the ground pins. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 2751 Engine Control Module: Description and Operation Powertrain Control Module - Operation Operation OPERATION The PCM supplies two regulated 5 volts supplies - a 5V primary and a 5V secondary (auxiliary) to the following sensors: - Camshaft Position Sensor (5V secondary) - Crankshaft Position Sensor (5V primary) - EGR Position feedback sensor (5V secondary) (if equipped) - Engine coolant temperature sensor (connected to 5V internal via a pull-up resistor) - Inlet Air Temperature Sensor (connected to 5V internal via a pullup resistor) - Knock sensor (connected to 5V internal via a pullup resistor) - Manifold absolute pressure sensor (5V secondary) - Oil Pressure Switch (connected to 5V internal via pullup resistor) - Pedal Value Sensor #1 (5V Primary) - Pedal Value Sensor #2 (5V Secondary) - SRV Position Feedback Sensor (5V Secondary) - Throttle Position Sensors (5V Primary) - Variable Line Pressure Sensor (5V Secondary) Powertrain Control Module POWERTRAIN CONTROL MODULE The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. NOTE: PCM Inputs: - Air Conditioning Controls - Battery Voltage - Brake Switch - Camshaft Position Sensor - Clutch Upstop Switch - Clutch Interlock - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor (Bus message) - Ignition Switch - Intake Air Temperature Sensor - Knock Sensor - Evaporative System Integrity Monitor Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 2752 - Manifold Absolute Pressure (MAP) Sensor - Oil Pressure Switch - Oxygen Sensors - Power Steering Pressure Switch - Speed Control Switches - Vehicle Speed Sensor (MTX-equipped models) NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Charging Indicator Lamp (Bus Message) - Proportional Purge Solenoid - Fuel Injectors - Generator Field - Ignition Coils - Malfunction Indicator (Check Engine) Lamp (Bus Message) - Manifold Flow Valve - Oxygen Sensors Heater Controls - Variable Valve Timing - Vehicle Speed (Manual Transmission) Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and EVAP canister purge operation. The PCM also determines the appropriate transmission shift schedule and shift points, depending on the present operating conditions and driver demand. The PCM regulates the cooling fan, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM also performs diagnostics. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. - Battery voltage - Coolant temperature - Exhaust gas content (oxygen sensor) - Engine speed (crankshaft position sensor) - Intake air temperature - Manifold absolute pressure - Throttle position The PCM adjusts ignition timing based on the following inputs. - Coolant temperature - Engine speed (crankshaft position sensor) - Knock sensor - Manifold absolute pressure - Throttle position - Transmission gear selection (park/neutral switch) - Intake air temperature The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs. - Air conditioning sense - Battery voltage - Brake switch - Coolant temperature - Engine speed (crankshaft position sensor) - Engine run time - Manifold absolute pressure - Power steering pressure switch - Throttle position - Transmission gear selection (park/neutral switch) - Vehicle distance (speed) The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive the signal within approximately 1 second of engine cranking, it deactivates the fuel pump. When these are deactivated, power is shut off to the fuel injectors, ignition coils, oxygen sensor heating elements and fuel pump. The PCM contains a voltage converter that changes battery voltage to a regulated 5 volts direct current to power the camshaft position sensor, crankshaft position sensor, manifold absolute pressure sensor, throttle position sensor, A/C pressure switch, A/C pressure transducer, and vehicle speed sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures TCM Initialization TRANSMISSION CONTROL MODULE INITIALIZATION NOTE: Refer to the following table when the Transmission Control Module (TCM) and/or transaxle has been replaced to determine if the TCM memory must be erased. INITIAL LEARN (BRAND-NEW MODULE, MEMORY ALREADY CLEAR) Battery must be connected. If the Totally Integrated Power Module (TIPM) is to be configured, configure the TIPM and then turn ignition key to OFF/LOCKED briefly, then back to RUN. The shifter must be in PARK or NEUTRAL, engine not running. 1. Turn the ignition key to RUN for 4 seconds to allow reading of new values. 2. Turn ignition key to OFF/LOCKED for 2 seconds to allow storing new values in EEROM. 3. Turn the ignition key to RUN, with scan tool clear DTCs. 4. Turn ignition key to OFF/LOCKED for 2 seconds. 5. After at least 7 seconds, read DTCs. 6. If DTCs resets See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Testing and Inspection RELEARN, AFTER REPLACING A TRANSAXLE 1. Turn ignition key to RUN. 2. Clear learning memory using the scan tool. 3. Turn the ignition key to OFF/LOCKED for 2 seconds. 4. Turn the ignition key to RUN Clear DTCs. 5. Turn the ignition key to OFF/LOCKED for 2 seconds. 6. Turn ignition key to RUN. 7. After at least 7 seconds, read DTCs. 8. If DTCs resets See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Testing and Inspection PCM/TCM Reprogramming PCM / TCM PROGRAMMING PCM / TCM FLASH PROGRAMING This procedure will need to be done when one or more of the following situations are true: 1. A vehicle's Powertrain Control Module (PCM) has been replaced. 2. A diagnostic trouble code (DTC) is set P1602 - PCM Not Programmed. 3. An updated calibration or software release is available for either the PCM or TCM ECUs. This procedure assumes that the wiTECH(TM) Vehicle Connection Interface (VCI) pod, StarSCAN(R) and StarMOBILE(R) devices are configured to your dealership's network with either a wired or wireless connection. The wiTECH(TM) VCI pod, StarSCAN(R) and StarMOBILE(R) must also be running at the latest operating system and software release level. For more help on how to network your StarSCAN(R) or StarMOBILE(R) reference the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the Download Center. For the wiTECH(TM) VCI pod use the "HELP" tab in the wiTECH(TM) Diagnostic Application. Table of contents 1. SECTION 1 - PCM / TCM FLASH PROCEDURE SECTION 1 - PCM / TCM FLASH PROCEDURE 2. REQUIRED TOOLS/EQUIPMENT REQUIRED TOOLS/EQUIPMENT: 3. TECH TIPS and INFORMATION TECH TIPS and INFORMATION: 4. PARTS REQUIRED PARTS REQUIRED Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2755 SECTION 1 - PCM / TCM FLASH PROCEDURE If using StarSCAN(R) or StarMOBILE(R) Desktop Client. Go To REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client If using StarMOBILE(R) Standalone Diagnostic Mode. Go To REPAIR PROCEDURE wiTECH(TM) Diagnostic Application REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the StarSCAN(R) or StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power on the StarSCAN(R) or StarMOBILE(R). If the StarMOBILE(R) is being used, launch the StarMOBILE(R) Desktop Client and connect to the appropriate StarMOBILE(R) device. 4. Retrieve the old ECU part number. From the tool's Home screen, a. Select "ECU View" b. Select "PCM/ECM" c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the Flash PCM/ECM screen for later reference. 5. Program the ECU as follows: a. Using the StarSCAN(R) / StarMOBILE(R) at the Home screen, select "ECU View" b. Select "PCM/ECM" c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File" and follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 4e, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. g. Select "Download to Scantool" h. Once the download is complete, select "Close" and then "Back" i. Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. j. When the PCM/ECM update is complete, select "OK" k. Verify that the part number at the top of the Flash PCM/ECM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 6. Continue to SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced. 7. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See Section 3 SECTION 3 - AUTHORIZED MODIFICATION LABEL for details). REPAIR PROCEDURE - wiTECH(TM) Diagnostic Application NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the wiTECH(TM) Vehicle Connection Interface (VCI) pod to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Launch the wiTECH(TM) Diagnostic Application and connect to the appropriate wiTECH(TM) device. 4. From the wiTECH(TM) Diagnostic Application Home screen, a. Select "HELP" b. Select "HELP CONTENTS" c. Follow the correct "HELP TOPIC" for the ECU being programmed SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES NOTE: Find the PCM/TCM Type for the vehicle, read and write down the steps, and then go to the step by step instructions for additional information on how to perform these procedures. STEP-BY-STEP INSTRUCTIONS If an EDC16-U31 PCM/ECM (2.0L) was replaced, perform the following additional steps and/or routines: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2756 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Program Variant Code If an EDC16-C2 PCM/ECM (2.2L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. IMA Rapid Calibration Test - Only on 06 PT AND up 4. Injector Quantity Adjustment - Only on 06 PT AND up If an EDC16-CP31 (3.0L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Diesel Particulate Filter (Used) Learning 4. NOx Catalyst (New) Initialization 5. Injector Quantity Adjustment 6. IMA Rapid Calibration Test 7. Fuel Mean Value Adaptation Initialization 8. Exhaust Throttle Plate Adaptive Learn Position If an EDC16-CP31-2 (2.8L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Injector Quantity Adjustment 4. Program Variant Code 5. ECU Replacement With Value Transfer if the ECU to be replaced is still responsive 6. ECU Replacement Without Value Transfer - if the ECU to be replaced is NOT responsive 7. Fuel Mean Value Adaptation Initialization 8. IMA Rapid Calibration Test 9. Set Oil Dilution Mass Value If a CM849 PCM/ECM (5.9L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped If a CM2100 PCM/ECM (6.7l) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Enable / Disable Vehicle Features - need to enable features 4. Injector Quantity Adjustment 5. Reset Regenerative Filter Timers 6. Mobile DeSoot - NO Minimum Required Soot Load If an Asian TCM was replaced, perform the following additional steps and/or routines: If an EATX TCM was replaced, perform the following additional steps and/or routines: If an NGC3 TCM ONLY was replaced, perform the following additional steps and/or routines: If an NGC4 TCM ONLY was replaced, perform the following additional steps and/or routines: 1. Quicklearn If an EGS TCM was replaced, perform the following additional steps and/or routines: 1. Initialize EGS STEP-BY-STEP INSTRUCTIONS Check PCM/ECM VIN Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2757 From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Check PCM/ECM VIN" and follow the on screen instructions. - When complete, select "Finish" Diesel Particulate Filter (Used) Learning From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Diesel Particulate Filter (Used) Learning" and follow the on screen instructions. - When complete, select "Finish" ECU Replacement with Value Transfer From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "ECU Replacement with Value Transfer" and follow the on screen instructions. - When complete, select "Finish" ECU Replacement without Value Transfer From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "ECU Replacement without Value Transfer" and follow the on screen instructions. - When complete, select "Finish" Enable / Disable Vehicle Features From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Enable / Disable Vehicle Features" and follow the on screen instructions. - When complete, select "Finish" Exhaust Throttle Plate Adaptive Learn Position From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Exhaust Throttle Plate Adaptive Learn Position" and follow the on screen instructions. - When complete, select "Finish" Fuel Mean Value Adaptation Initialization From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Fuel Mean Value Adaptation Initialization" and follow the on screen instructions. - When complete, select "Finish" IMA Rapid Calibration From the "Home" screen, select "ECU View" Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2758 - Select "PCM/ECM" - Select "Misc. Functions" - Select "IMA Rapid Calibration Test" and follow the on screen instructions. - When complete, select "Finish" Initialize EGS From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Initialize EGS" and follow the on screen instructions. - When complete, select "Finish" Injector Quantity Adjustment From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Injector Quantity Adjustment" and follow the on screen instructions. - When complete, select "Finish" Mobile DeSoot - NO Minimum Required Soot Load From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Mobile DeSoot - NO Minimum Required Soot Load" and follow the on screen instructions. - When complete, select "Finish" NOx Catalyst (New) Initialization From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "NOx Catalyst (New) Initialization" and follow the on screen instructions. - When complete, select "Finish" PCM/ECM Replaced The vehicle pin (Personal Identification Number) will be required to complete the routine. This information may be obtained in three ways: 1. The original selling invoice 2. DealerCONNECT > Parts > Key Codes 3. Contacting the District Manager. From the "Home" screen, select "ECU View" - Select "WIN" - Select "Misc. Functions" - Select "PCM/ECM Replaced" and follow the on screen instructions. - When complete, select "Finish" Program Variant Code From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Program Variant Code" and follow the on screen instructions. - When complete, select "Finish" Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2759 Quicklearn From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Quicklearn" and follow the on screen instructions. - When complete, select "Finish" Reset Regenerative Filter Timers From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Reset Regenerative Filter Times" and follow the on screen instructions. - When complete, select "Finish" Set Oil Dilution Mass Value From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Set Oil Dilution Mass Value" and follow the on screen instructions. - When complete, select "Finish" SECTION 3 - AUTHORIZED MODIFICATION LABEL NOTE: The following step is required by law when reprogramming a PCM/ECM and/or TCM. Type the necessary information on the "Authorized Modification Label" and attach near the VECI label. 1. Powertrain Control / Transmission Control Module Part Numbers (Insert P/Ns) Used 2. Change Authority: TSB XX--XX 3. Dealer Code: XXXXX 4. Date: XX-XX-XX REQUIRED TOOLS/EQUIPMENT: TECH TIPS and INFORMATION: CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2760 1. The wiTECH(TM) Diagnostic Application is the preferred method for flashing any Chrysler vehicle ECU. For more information, training tutorials are available under the "HELP" tab in the wiTECH(TM) Diagnostic Application, under the 'Training Aids' link. 2. To use the StarMOBILE(R) in Pass-Through Mode requires that your StarMOBILE(R) is connected to the dealerships network via a wired or wireless connection. For more information on how to use the StarMOBILE in Pass-Through Mode see the StarMOBILE(R) training tutorials available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Training Aids' link, under the 'Training Aids' link. 3. If the flash process is interrupted or aborted, the flash should be restarted. 4. Due to the PCM/ECM / TCM programming procedure, a DTC may be set in other ECUs within the vehicle. Some DTCs may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 5. Do not allow the battery charger to time out or the charging rate to climb above 13.5 Volts during the flash process. 6. The StarSCAN(R) and StarMOBILE(R) diagnostic tools fully support Internet connectivity and must be configured for your dealership's network. For help on setting up your StarSCAN(R) / StarMOBILE(R) for the dealership's network, refer to the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the download center. 7. The operating software in the StarSCAN(R) and StarMOBILE(R) must be programmed with the latest software release level. The software level is visible in the blue header at the top of the StarSCAN(R) and StarMOBILE(R) Desktop Client screens. For instructions on how to update your scan tool, refer to the StarSCAN(R) / StarMOBILE(R) Software Update guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the download center. PARTS REQUIRED Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2761 The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2762 If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2763 Engine Control Module: Removal and Replacement Powertrain Control Module - Removal REMOVAL USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. To avoid possible voltage spike damage to PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable. 2. Unlock and disconnect the electrical connectors from PCM. 3. Remove the air cleaner box. 4. Remove the three mounting bolts. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2764 5. Tip module out and remove from bracket. Powertrain Control Module - Installation INSTALLATION USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Tip module into bracket. 2. Install three mounting bolts and tighten to 9 Nm (80 in. lbs.) torque. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2765 3. Check pins in electrical connectors for damage. Repair as necessary. 4. Connect electrical connectors and lock. 5. Install air cleaner box. 6. Connect negative battery cable. 7. Use the scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Sensor: Service and Repair Removal EXHAUST PRESSURE SENSOR 1. Disconnect and isolate negative battery cable. 2. Remove electrical connector at pressure differential sensor (2). 3. Remove upstream exhaust pressure tube (4) from catalytic converter 4. Remove downstream pressure tube (6) from catalytic converter. 5. Remove pressure differential sensor mounting bolt. 6. Remove pressure differential sensor (2) and tubing (7) from vehicle. 7. Remove tubing (7) from pressure differential sensor (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal > Page 2770 Exhaust Pressure Sensor: Service and Repair Installation EXHAUST PRESSURE SENSOR 1. Install tubing (7) on pressure differential sensor (2). 2. Position pressure differential sensor (2) and tubing (7). 3. Install pressure differential sensor mounting bolt (3). Tighten to 10 Nm (89 in. lbs.). 4. Install downstream pressure tube (6) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.). 5. Install upstream pressure tube (4) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.) 6. Position electrical connector (1) into bracket. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2774 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way Fuel Level Sensor: Diagrams Fuel Pump Module (FWD) (Body) 4 Way Connector (FWD) - (BODY) 4 WAY MODULE-FUEL PUMP (FWD) - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way > Page 2777 Fuel Level Sensor: Diagrams Fuel Pump Module C1 (AWD) (Body) 5 Way Connector C1 (AWD) - (BODY) 5 WAY MODULE-FUEL PUMP (AWD) - (BODY) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way > Page 2778 Fuel Level Sensor: Diagrams Fuel Pump Module C2 (AWD) (Body) 2 Way Connector C2 (AWD) - (BODY) 2 WAY MODULE-FUEL PUMP (AWD) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Level Sensor: Description and Operation Fuel Pump Module - Description DESCRIPTION - FUEL PUMP MODULE The fuel pump module is located on the top left side of the fuel tank. The fuel pump module contains the following components: - Mounting flange - Electric fuel pump - Fuel pump reservoir - Inlet strainer - Fuel pressure regulator - Fuel level sending unit - Fuel filter The fuel level sending unit (3) is the only serviceable component of the fuel pump module. If the electric fuel pump, fuel pressure regulator or fuel filter requires service, the fuel pump module must be replaced as an assembly. DESCRIPTION The fuel pump module is installed in the top of the fuel tank. The fuel pump module contains the following: - Electric fuel pump - Fuel pump reservoir Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 2781 - Inlet strainer - Fuel pressure regulator - Fuel gauge sending unit - Fuel supply line connection - Fuel Filter NOTE: The fuel level sending unit is the only serviceable item. If the fuel pump, fuel pressure regulator or fuel filters need service, replace the fuel pump module as an assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 2782 Fuel Level Sensor: Description and Operation Fuel Pump Module - Operation OPERATION - FUEL PUMP MODULE An electric fuel pump is located within the fuel pump module. The electric fuel pump is a positive displacement, immersible pump with a permanent magnet electric motor capable of creating 860 kPa (125 psi) of operating pressure. The fuel pressure regulator limits fuel pressure to 400 kPa (58 psi). The fuel gauge is controlled by the instrument cluster circuit board based upon cluster programming and a hard wired input received by the cluster from the fuel level sending unit on the module in the fuel tank. The instrument cluster continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. This information is available to other vehicle control modules via the Controller Area Network (CAN) data bus. Fuel gauge diagnosis is conducted as part ofthe instrument cluster circuitry. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Level Sensor: Service and Repair Fuel Pump Module - Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. 1. Perform Fuel System Pressure Release procedure. See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair 2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose. 3. Remove the negative battery cable. 4. Remove the rear seat cushion. 5. Rear seat cushion loose. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2785 6. Remove plastic cover. 7. Clean top of tank to remove loose dirt and debris. 8. Use special tool #9340 to remove left side module lock ring. 9. Note the fuel pump location on the top of the fuel tank. NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2786 10. Pull module up out of fuel tank, make sure that you do not spill fuel inside of vehicle. 11. Drain fuel from fuel pump module. Do not spill fuel in interior of vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2787 Fuel Level Sensor: Service and Repair Fuel Pump Module - Installation INSTALLATION NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. 1. Wipe seal area of tank clean. Place a new seal between the tank threads and the pump module opening. 2. Install module. 3. Position fuel pump module in tank. Make sure the alignment tab lines up on the fuel tank and pump module for Gas or Diesel fuel tanks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2788 4. While holding the pump module in position, install lock ring and use special tool Spanner Wrench #9340 to tighten lock ring. 5. Install plastic cover. 6. Install rear cushion. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 2789 7. Install the negative battery cable. 8. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. 9. Fill fuel tank with clean fuel. Use the Scan Tool to pressurize the system and check for leaks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2794 It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2795 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2796 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2797 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2798 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2799 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2800 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2801 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2802 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2803 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2804 Information Bus: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2805 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2806 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2807 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Communication - Description Information Bus: Description and Operation Communication - Description DESCRIPTION The primary on-board communication network between microprocessor-based electronic control modules in this vehicle is the Controller Area Network (CAN) data bus system. A data bus network minimizes redundant wiring connections; and, at the same time, reduces wire harness complexity, sensor current loads and controller hardware by allowing each sensing device to be connected to only one module (also referred to as a node). Each node reads, then broadcasts its sensor data over the bus for use by all other nodes requiring that data. Each node ignores the messages on the bus that it cannot use. The CAN bus is a two-wire multiplex system. Multiplexing is any system that enables the transmission of multiple messages over a single channel or circuit. The CAN bus is used for communication between most vehicle nodes. However, in addition to the CAN bus network, certain nodes may also be equipped with a Local Interface Network (LIN) data bus. The LIN data bus is a single wire low-speed (9.6 Kbps) serial link bus used to provide direct communication between a LIN master module and certain switch or sensor inputs. There are actually three separate CAN bus systems used in the vehicle. They are designated: the CAN-B, the CAN-C and the Diagnostic CAN-C. The CAN-B and CAN-C systems provide on-board communication between all nodes in the vehicle. The CAN-C is the faster of the two systems providing near real-time communication (500 Kbps), but is less fault tolerant than the CAN-B system. The CAN-C is used typically for communications between more critical nodes, while the slower (83.3 Kbps), but more fault tolerant CAN-B system is used for communications between less critical nodes. The CAN-B fault tolerance comes from its ability to revert to a single wire communication mode if there is a fault in the bus wiring. The added speed of the CAN data bus is many times faster than previous data bus systems. This added speed facilitates the addition of more electronic control modules or nodes and the incorporation of many new electrical and electronic features in the vehicle. The Diagnostic CAN-C bus is also capable of 500 Kbps communication, and is sometimes informally referred to as the CAN-D system to differentiate it from the other high speed CAN-C bus. The Diagnostic CAN-C is used exclusively for the transmission of diagnostic information between the Totally Integrated Power Module/Central GateWay (TIPM or TIPMCGW) and a diagnostic scan tool connected to the industry-standard 16-way Data Link Connector (DLC) located beneath the instrument panel on the driver side of the vehicle. The TIPM is located in the engine compartment near the battery. The central CAN gateway or hub module integral to the TIPM is connected to all three CAN buses. This gateway physically and electrically isolates the CAN buses from each other and coordinates the bi-directional transfer of messages between them. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Communication - Description > Page 2810 Information Bus: Description and Operation Communication - Operation OPERATION The Controller Area Network (CAN) data bus allows all electronic modules or nodes connected to the bus to share information with each other. Regardless of whether a message originates from a module on the lower speed CAN-B bus or on the higher speed CAN-C or CAN-D bus, the message structure and layout is similar, which allows the Totally Integrated Power Module/Central GateWay (TIPM or TIPMCGW) to process and transfer messages between the CAN buses. The TIPM also stores a Diagnostic Trouble Code (DTC) for certain bus network faults. All modules (also referred to as nodes) transmit and receive messages over one of these buses. Data exchange between nodes is achieved by serial transmission of encoded data messages. Each node can both send and receive serial data simultaneously. Each digital bit of a CAN bus message is carried over the bus as a voltage differential between the two bus circuits which, when strung together, form a message. Each node uses arbitration to sort the message priority if two competing messages are attempting to be broadcast at the same time. The Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) is the Local Interface Network (LIN) master module in this vehicle and it gathers information from the compass module, the instrument panel switch bank, the Steering Control Module (SCM), and the Heated Seat Module (HSM) through the LIN data bus. There is also LIN bus communication between the individual Tire Pressure Monitor (TPM) transponders and the Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM). Both the EMIC and the SKREEM either act directly upon the information received through the LIN data bus, relay the information to other nodes in the vehicle using electronic messages placed on the CAN bus, or both. The voltage network used to transmit messages requires biasing and termination. Each module on the CAN bus network provides its own biasing and termination. There are two types of nodes used in the CAN bus network. On the CAN-C bus, a dominant node has a 120 ohm termination resistance, while a non-dominant (or recessive) node has about a 2500 to 3000 ohm (2.5 to 3.0 kilo Ohms) termination resistance. The dominant nodes on the CAN-C bus are the TIPM and the Powertrain Control Module (PCM). The termination resistance of two dominant nodes is combined in parallel to provide a total of about 60 ohms. This resistance value may vary somewhat by application, depending upon the number of non-dominant nodes on the CAN-C bus. On the CAN-D bus (or Diagnostic CAN-C) all of the 60 ohm termination resistance is present in the Central GateWay (TIPMCGW). NOTE: All measurement of termination resistance is done with the vehicle battery disconnected. NOTE: Termination resistance of a CAN-B node cannot be verified with a Digital Multi-Meter (DMM) or Digital Volt-Ohm Meter (DVOM). The transceiver of each CAN-B node connects to termination resistors internally. When the vehicle battery is disconnected, the internal connections of all CAN-B node transceivers are switched open, disconnecting the termination resistors. Therefore, the total bus resistance measured under these conditions will be extremely high or infinite, which does not accurately reflect the actual termination resistance of the CAN-B bus. The communication protocol being used for the CAN data bus is a non-proprietary, open standard adopted from the Bosch CAN Specification 2.0b. The CAN-C is the faster of the two primary buses in the CAN bus system, providing near real-time communication (500 Kbps). The CAN bus nodes are connected in parallel to the two-wire bus using a twisted pair, where the wires are wrapped around each other to provide shielding from unwanted electromagnetic induction, thus preventing interference with the relatively low voltage signals being carried through them. The twisted pairs have between 33 and 50 twists per meter (yard). While the CAN bus is operating (active), one of the bus wires will carry a higher voltage and is referred to as the CAN High or CAN bus (+) wire, while the other bus wire will carry a lower voltage and is referred to as the CAN Low or CAN bus (-) wire. Refer to the CAN Bus Voltages table. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Communication - Description > Page 2811 In order to minimize the potential effects of Ignition-OFF Draw (IOD), the CAN-B network employs a sleep strategy. However, a network sleep strategy should not be confused with the sleep strategy of the individual nodes on that network, as they may differ. For example: The CAN-C bus network is awake only when the ignition switch is in the ON or START positions; however, the TIPM, which is on the CAN-C bus, may still be awake with the ignition switch in the ACCESSORY or UNLOCK positions. The integrated circuitry of an individual node may be capable of processing certain sensor inputs and outputs without the need to utilize network resources. The CAN-B bus network remains active until all nodes on that network are ready for sleep. This is determined by the network using tokens in a manner similar to polling. When the last node that is active on the network is ready for sleep, and it has already received a token indicating that all other nodes on the bus are ready for sleep, it broadcasts a bus sleep acknowledgment message that causes the network to sleep. Once the CAN-B bus network is asleep, any node on the bus can awaken it by transmitting a message on the network. The TIPM will keep either the CAN-B or the CAN-C bus awake for a timed interval after it receives a diagnostic message for that bus over the Diagnostic CAN-C bus. In the CAN system, available options are configured into the TIPM at the assembly plant, but additional options can be added in the field using the diagnostic scan tool. The configuration settings are stored in non-volatile memory. The TIPM also has two 64-bit registers, which track each of the as-built and currently responding nodes on the CAN-B and CAN-C buses. The TIPM stores a Diagnostic Trouble Code (DTC) in one of two caches for any detected active or stored faults in the order in which they occur. One cache stores powertrain (P-Code), chassis (C-Code) and body (B-Code) DTCs, while the second cache is dedicated to storing network (U-Code) DTCs. If there are intermittent or active faults in the CAN network, a diagnostic scan tool connected to the Diagnostic CAN-C bus through the 16-way Data Link Connector (DLC) may only be able to communicate with the TIPM. To aid in CAN network diagnosis, the TIPM will provide CAN-B and CAN-C network status information to the scan tool using certain diagnostic signals. In addition, the transceiver in each node on the CAN-C bus will identify a bus off hardware failure, while the transceiver in each node on the CAN-B bus will identify a general bus hardware failure. The transceivers for some CAN-B nodes will also identify certain failures for both CAN-B bus signal wires. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2815 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2816 Knock Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-KNOCK (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal REMOVAL The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Disconnect the negative battery cable. 2. Remove the bolt holding the knock sensor. 3. Remove sensor with electrical connector attached. 4. Disconnect electrical connector from knock sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 2819 5. Remove the knock sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 2820 Knock Sensor: Service and Repair Knock Sensor - Installation INSTALLATION The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Attach electrical connector to knock sensor. 2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening effects knock sensor performance, possibly causing improper spark control. 3. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Main Relay is located in the Fuse/Relay block. Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2824 Main Relay (Computer/Fuel System): Diagrams Connector - (IN F/RB) RELAY-MAIN - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2828 Manifold Pressure/Vacuum Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-MAP (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Operation Manifold Pressure/Vacuum Sensor: Description and Operation Operation OPERATION The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 volt and full scale is 4.5 volt. For a pressure swing of 0 - 15 psi the voltage changes 4.0 volt. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key on. The difference between current and what it was at key on is manifold vacuum. During key On (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in your work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC1 transmissions only, via the PCI bus) - Idle speed - Decel fuel shutoff The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 88 kPa (26 in. Hg). Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 101 kPa (29.92 in. Hg). For every 30.5 meters (100 feet) of altitude barometric pressure drops.33 kPa (0.10 in. Hg). If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Operation > Page 2831 Manifold Pressure/Vacuum Sensor: Description and Operation Description DESCRIPTION The MAP sensor mounts to the intake manifold. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Page 2832 Manifold Pressure/Vacuum Sensor: Testing and Inspection CHECKING THE MAP SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. MAP SENSOR WIRING OR CONNECTORS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Page 2833 NOTE: Diagnose and repair any MAP Sensor circuit DTCs before proceeding with this test. NOTE: Diagnose and repair any sensor supply or system voltage DTCs before proceeding with this test. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. MAP VACUUM/BAROMETRIC PRESSURE 1. With a scan tool, read the Barometric Pressure. NOTE: The Barometric Pressure should be approximately equal to the actual barometric pressure. If necessary, compare the Barometric Pressure value of the tested vehicle to the value of a known good vehicle of a similar make and model. 2. Connect a vacuum gauge to a manifold vacuum source. 3. Start the engine. NOTE: If engine will not idle, maintain a constant RPM above idle. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 4. With the scan tool, read the MAP Sensor vacuum. NOTE: The scan tool reading for MAP vacuum should be within 1" of the vacuum gauge reading. Were any problems found? Yes - Go to 4 No - Go to 3 3. MAP SENSOR VOLTAGE 1. With the scan tool, monitor the MAP Sensor signal voltage. 2. With the engine idling in neutral or park, snap the throttle. NOTE: The MAP Sensor signal voltage should change from below 2.0 volts at idle to above 3.5 volts at wide open throttle. Were any problems found? Yes - Go to 4 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Page 2834 No - Test complete. 4. (F856) 5 VOLT SUPPLY CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (F856) 5 Volt Supply circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 5 No - Repair the (F856) 5 Volt Supply circuit for excessive resistance. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 5. (K1) MAP SIGNAL CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K1) MAP Signal circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 No - Repair the (K1) MAP Signal circuit for excessive resistance. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the MAP Sensor harness connector and by Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Page 2835 probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the (K900) Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. MAP SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the MAP Sensor. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect electrical connector from manifold absolute pressure (MAP) sensor. 3. Remove screw from MAP sensor. 4. Remove MAP sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 2838 Manifold Pressure/Vacuum Sensor: Service and Repair Installation INSTALLATION 1. Install manifold absolute pressure (MAP) sensor to intake manifold. 2. Tighten screw to 4.5 Nm (40 in. lbs.). 3. Connect electrical connector to sensor. 4. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 2843 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Powertrain) 4 Way Oxygen Sensor: Diagrams Oxygen Sensor 1/1 (Powertrain) 4 Way Connector (GAS) - (POWERTRAIN) 4 WAY SENSOR-OXYGEN 1/1 (GAS) - (POWERTRAIN) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Powertrain) 4 Way > Page 2846 Oxygen Sensor: Diagrams Oxygen Sensor 1/2 (Engine Compartment) 4 Way Connector (GAS) - (ENGINE COMPARTMENT) 4 WAY SENSOR-OXYGEN 1/2 (GAS) - (ENGINE COMPARTMENT) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2847 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Oxygen Sensor: Description and Operation Description DESCRIPTION The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. The downstream heated oxygen sensor threads into the system depending on emission package. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description > Page 2850 Oxygen Sensor: Description and Operation Operation OPERATION Separate upstream and downstream grounds are used on the NGC vehicles (4 Cyl.). As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The O2 sensors produce a constant 2.5 volts on NGC vehicles, depending upon the oxygen content of the exhaust gas. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produce a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, which can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2 sensor's input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The NGC Controller has a common ground for the heater in the O2S. 12 volts is supplied to the heater in the O2S by the NGC controller. Both the upstream and downstream O2 sensors for NGC are pulse width modulation (PWM). NOTE: When replacing an O2 Sensor, the PCM RAM memory must be cleared, either by disconnecting the PCM C-1 connector or momentarily disconnecting the Battery negative terminal. The NGC learns the characteristics of each O2 heater element and these old values should be cleared when installing a new O2 sensor. The customer may experience driveability issues if this is not performed. UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 2.5 to 3.5 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 2.5 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 3.5 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. This is also used to establish the upstream O2 goal voltage (switching point). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 2851 Oxygen Sensor: Testing and Inspection CHECKING THE OXYGEN SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. OXYGEN SENSOR, WIRING OR CONNECTORS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 2852 NOTE: Diagnose and repair any O2 sensor or rationality DTCs before proceeding with this test. NOTE: When performing this procedure as part of another diagnostic process, it may be necessary to repeat this test for all of the oxygen sensors on the vehicle. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen sensor and the Powertrain Control Module (PCM). 3. Look for any chafed, pierced, pinched or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the PCM VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. OXYGEN SENSOR VOLTAGE 1. Start the engine and allow it to reach normal operating temperature. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 2. With a scan tool, monitor all O2 Sensor voltage readings. Is the voltage switching between 2.5 and 3.4 volts for all O2 sensors? Yes - Go To 3 No - Go To 4 3. O2 SENSOR HEATER OPERATION 1. Turn the ignition off. NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0 volts. 2. Turn the ignition on. 3. With a scan tool, actuate the O2 Sensor heater. 4. With the scan tool, monitor O2 Sensor voltage for at least two minutes. Does the voltage stay above 4.5 volts? Yes - Go To 4 No - Test complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 2853 4. O2 SENSOR 1. Turn the ignition off. NOTE: Check for contaminants that may cause improper O2 Sensor operation, such as contaminated fuel, unapproved silicone, or evidence of oil or coolant. 2. Disconnect the O2 Sensor harness connector. 3. Turn the ignition on. 4. With a scan tool, monitor the O2 Sensor voltage. NOTE: The voltage should be approximately 5.0 volts with the connector disconnected. 5. Connect a jumper wire between the signal circuit and the return circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from 5.0 volts to 2.5 volts with the jumper wire in place. Is the O2 Sensor voltage displayed on the scan tool as described? Yes - Replace the O2 Sensor. - Perform the PCM VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 5 5. O2 SENSOR SIGNAL CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Signal circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor signal circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the PCM VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 6 6. O2 SENSOR RETURN CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Return circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor return circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the PCM VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 7 7. POWERTRAIN CONTROL MODULE (PCM) 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the O2 sensor and the PCM. 2. Look for any chafed, pierced, pinched or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Monitor the scan tool data relative to the components tested in this procedure and wiggle test the wiring and connectors. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 2854 5. Look for the data to change or for a DTC to set during the wiggle test. 6. Search for any Technical Service Bulletins (TSBs) that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Replace and program the Powertrain Control Module (PCM). - Perform the PCM VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal Oxygen Sensor: Service and Repair Removal 2.4L DOWNSTREAM OXYGEN SENSOR (1/2) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wires going into oxygen sensor. Damage to the oxygen sensor may occur. NOTE: Use an oxygen sensor (O2S) removal tool for this procedure. 1. Raise and support vehicle. 2. Disconnect O2S wire harness mounting clips from engine or body, if equipped. 3. Disconnect O2S pigtail harness connector (1) from engine wiring harness. 4. Remove O2S (3) from exhaust pipe (2). UPSTREAM OXYGEN SENSOR (1/1) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wires going into oxygen sensor. Damage to the oxygen Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 2857 sensor may occur. NOTE: Use an oxygen sensor (O2S) removal tool for this procedure. 1. Raise and support vehicle. 2. Disconnect O2S wire harness mounting clips from engine or body, if equipped. 3. Disconnect O2S pigtail harness connector (1) from engine wiring harness. 4. Remove O2S (3) from maniverter (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 2858 Oxygen Sensor: Service and Repair Installation 2.4L DOWNSTREAM OXYGEN SENSOR (1/2) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted back to their original positions on engine or body to prevent mechanical damage to wiring. NOTE: Use an O2S removal tool for this procedure. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new O2S. 1. Install O2 sensor (3) to exhaust pipe (2). Tighten to 41 Nm (30 ft. lbs.). 2. Connect O2 sensor pigtail harness connector (1) to engine wiring harness. 3. Connect O2S wire harness mounting clips to engine or body, if equipped. UPSTREAM OXYGEN SENSOR (1/1) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 2859 CAUTION: When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted back to their original positions on engine or body to prevent mechanical damage to wiring. NOTE: Use an O2S removal tool for this procedure. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new O2S. 1. Install O2 sensor (3) to maniverter (2). Tighten to 41 Nm (30 ft. lbs.). 2. Connect O2 sensor pigtail harness connector (1) to engine wiring harness. 3. Connect O2S wire harness mounting clips to engine or body, if equipped. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2869 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2870 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2871 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2872 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2873 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2874 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2875 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2876 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2877 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2878 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2879 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: Recalls Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC's P0139/P0571 Set NUMBER: 18-018-09 GROUP: Vehicle Performance DATE: June 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For Diagnostic Trouble Code P0139 Or P0571 Is Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey 2009 (JS) Sebring/Avenger/Sebring Convertible 2009 (PM) Caliber 2009 (MK) Compass/Patriot NOTE: This bulletin applies to: - 2009 JS vehicles equipped with a 2.0L/2.4L Engine (Sales Code ECN or EDG or ED3) built before July 27, 2009 (MDH 0727XX) - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before July 27, 2009 (MDH 0727XX) - 2009 PM/MK vehicles equipped with a 1.8L, 2.0L or 2.4L engines (Sales Codes EBA, ECN and ED3) built before July 10, 2009 (MDH 0710XX) SYMPTOM/CONDITION: Some customers may experience a MIL illumination. The MIL is for P0139 - 02 Sensor 1/2 Slow Response. Further investigation by the technician may also find DTC P0571. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other then the ones listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set > Page 2889 If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0139/P0571 Set NUMBER: 18-018-09 GROUP: Vehicle Performance DATE: June 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For Diagnostic Trouble Code P0139 Or P0571 Is Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey 2009 (JS) Sebring/Avenger/Sebring Convertible 2009 (PM) Caliber 2009 (MK) Compass/Patriot NOTE: This bulletin applies to: - 2009 JS vehicles equipped with a 2.0L/2.4L Engine (Sales Code ECN or EDG or ED3) built before July 27, 2009 (MDH 0727XX) - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before July 27, 2009 (MDH 0727XX) - 2009 PM/MK vehicles equipped with a 1.8L, 2.0L or 2.4L engines (Sales Codes EBA, ECN and ED3) built before July 10, 2009 (MDH 0710XX) SYMPTOM/CONDITION: Some customers may experience a MIL illumination. The MIL is for P0139 - 02 Sensor 1/2 Slow Response. Further investigation by the technician may also find DTC P0571. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other then the ones listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set > Page 2895 If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2900 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2901 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2902 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2903 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2904 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2905 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2906 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2907 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2908 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2909 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2910 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: All Technical Service Bulletins Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0139/P0571 Set NUMBER: 18-018-09 GROUP: Vehicle Performance DATE: June 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For Diagnostic Trouble Code P0139 Or P0571 Is Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey 2009 (JS) Sebring/Avenger/Sebring Convertible 2009 (PM) Caliber 2009 (MK) Compass/Patriot NOTE: This bulletin applies to: - 2009 JS vehicles equipped with a 2.0L/2.4L Engine (Sales Code ECN or EDG or ED3) built before July 27, 2009 (MDH 0727XX) - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before July 27, 2009 (MDH 0727XX) - 2009 PM/MK vehicles equipped with a 1.8L, 2.0L or 2.4L engines (Sales Codes EBA, ECN and ED3) built before July 10, 2009 (MDH 0710XX) SYMPTOM/CONDITION: Some customers may experience a MIL illumination. The MIL is for P0139 - 02 Sensor 1/2 Slow Response. Further investigation by the technician may also find DTC P0571. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other then the ones listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set > Page 2920 If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2926 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2927 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2928 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2929 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2930 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2931 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2932 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2933 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2934 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2935 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 2936 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > NHTSA08V528000 > Oct > 08 > Recall 08V528000: PCM Replacement Engine Control Module: All Technical Service Bulletins Recall 08V528000: PCM Replacement VEHICLE MAKE/MODEL: MODEL YEAR(S): Chrysler/Sebring 2009 Dodge/Avenger 2009 Dodge/Caliber 2009 Dodge/Journey 2009 Jeep/Compass 2009 Jeep/Patriot 2009 MANUFACTURER: Chrysler LLC MFR'S REPORT DATE: October 07, 2008 NHTSA CAMPAIGN ID NUMBER: 08V528000 NHTSA ACTION NUMBER: N/A COMPONENT: Power Train: Automatic Transmission: Control module (TCM, PCM) POTENTIAL NUMBER OF UNITS AFFECTED: 712 SUMMARY: Chrysler is recalling 712 M/Y 2009 Sebring, Dodge Caliber, Avenger, Journey, Jeep Patriot, and Compass vehicles. A new adhesive used in the Power Train Control Module (PCM) manufacturing process can cause the printed circuit board to break. CONSEQUENCE: This can cause the engine to stall and cause a crash without warning. REMEDY: Dealers will replace the PCM free of charge. The recall is expected to begin during October 2008. Owners may contact Chrysler at 1-800-853-1403. NOTES: Chrysler recall No. H33. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2941 Engine Control Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2942 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way Engine Control Module: Diagrams Powertrain Control Module C1 (Engine Compartment) 58 Way Connector C1 (GAS) - (ENGINE COMPARTMENT) 58 WAY MODULE-POWERTRAIN CONTROL (GAS) - (ENGINE COMPARTMENT) 58 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2945 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2946 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2947 Engine Control Module: Diagrams Powertrain Control Module C2 (Engine Compartment) 96 Way Connector C2 (GAS) - (ENGINE COMPARTMENT) 96 WAY MODULE-POWERTRAIN CONTROL (GAS) - (ENGINE COMPARTMENT) 96 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2948 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2949 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 (Engine Compartment) 58 Way > Page 2950 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description Engine Control Module: Description and Operation Powertrain Control Module - Description Sensor Return - PCM Input SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). PCM Ground PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded separately from the ground pins. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 2953 Engine Control Module: Description and Operation Powertrain Control Module - Operation Operation OPERATION The PCM supplies two regulated 5 volts supplies - a 5V primary and a 5V secondary (auxiliary) to the following sensors: - Camshaft Position Sensor (5V secondary) - Crankshaft Position Sensor (5V primary) - EGR Position feedback sensor (5V secondary) (if equipped) - Engine coolant temperature sensor (connected to 5V internal via a pull-up resistor) - Inlet Air Temperature Sensor (connected to 5V internal via a pullup resistor) - Knock sensor (connected to 5V internal via a pullup resistor) - Manifold absolute pressure sensor (5V secondary) - Oil Pressure Switch (connected to 5V internal via pullup resistor) - Pedal Value Sensor #1 (5V Primary) - Pedal Value Sensor #2 (5V Secondary) - SRV Position Feedback Sensor (5V Secondary) - Throttle Position Sensors (5V Primary) - Variable Line Pressure Sensor (5V Secondary) Powertrain Control Module POWERTRAIN CONTROL MODULE The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. NOTE: PCM Inputs: - Air Conditioning Controls - Battery Voltage - Brake Switch - Camshaft Position Sensor - Clutch Upstop Switch - Clutch Interlock - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Fuel Level Sensor (Bus message) - Ignition Switch - Intake Air Temperature Sensor - Knock Sensor - Evaporative System Integrity Monitor Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 2954 - Manifold Absolute Pressure (MAP) Sensor - Oil Pressure Switch - Oxygen Sensors - Power Steering Pressure Switch - Speed Control Switches - Vehicle Speed Sensor (MTX-equipped models) NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Charging Indicator Lamp (Bus Message) - Proportional Purge Solenoid - Fuel Injectors - Generator Field - Ignition Coils - Malfunction Indicator (Check Engine) Lamp (Bus Message) - Manifold Flow Valve - Oxygen Sensors Heater Controls - Variable Valve Timing - Vehicle Speed (Manual Transmission) Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and EVAP canister purge operation. The PCM also determines the appropriate transmission shift schedule and shift points, depending on the present operating conditions and driver demand. The PCM regulates the cooling fan, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM also performs diagnostics. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. - Battery voltage - Coolant temperature - Exhaust gas content (oxygen sensor) - Engine speed (crankshaft position sensor) - Intake air temperature - Manifold absolute pressure - Throttle position The PCM adjusts ignition timing based on the following inputs. - Coolant temperature - Engine speed (crankshaft position sensor) - Knock sensor - Manifold absolute pressure - Throttle position - Transmission gear selection (park/neutral switch) - Intake air temperature The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs. - Air conditioning sense - Battery voltage - Brake switch - Coolant temperature - Engine speed (crankshaft position sensor) - Engine run time - Manifold absolute pressure - Power steering pressure switch - Throttle position - Transmission gear selection (park/neutral switch) - Vehicle distance (speed) The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive the signal within approximately 1 second of engine cranking, it deactivates the fuel pump. When these are deactivated, power is shut off to the fuel injectors, ignition coils, oxygen sensor heating elements and fuel pump. The PCM contains a voltage converter that changes battery voltage to a regulated 5 volts direct current to power the camshaft position sensor, crankshaft position sensor, manifold absolute pressure sensor, throttle position sensor, A/C pressure switch, A/C pressure transducer, and vehicle speed sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures TCM Initialization TRANSMISSION CONTROL MODULE INITIALIZATION NOTE: Refer to the following table when the Transmission Control Module (TCM) and/or transaxle has been replaced to determine if the TCM memory must be erased. INITIAL LEARN (BRAND-NEW MODULE, MEMORY ALREADY CLEAR) Battery must be connected. If the Totally Integrated Power Module (TIPM) is to be configured, configure the TIPM and then turn ignition key to OFF/LOCKED briefly, then back to RUN. The shifter must be in PARK or NEUTRAL, engine not running. 1. Turn the ignition key to RUN for 4 seconds to allow reading of new values. 2. Turn ignition key to OFF/LOCKED for 2 seconds to allow storing new values in EEROM. 3. Turn the ignition key to RUN, with scan tool clear DTCs. 4. Turn ignition key to OFF/LOCKED for 2 seconds. 5. After at least 7 seconds, read DTCs. 6. If DTCs resets See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Testing and Inspection RELEARN, AFTER REPLACING A TRANSAXLE 1. Turn ignition key to RUN. 2. Clear learning memory using the scan tool. 3. Turn the ignition key to OFF/LOCKED for 2 seconds. 4. Turn the ignition key to RUN Clear DTCs. 5. Turn the ignition key to OFF/LOCKED for 2 seconds. 6. Turn ignition key to RUN. 7. After at least 7 seconds, read DTCs. 8. If DTCs resets See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Testing and Inspection PCM/TCM Reprogramming PCM / TCM PROGRAMMING PCM / TCM FLASH PROGRAMING This procedure will need to be done when one or more of the following situations are true: 1. A vehicle's Powertrain Control Module (PCM) has been replaced. 2. A diagnostic trouble code (DTC) is set P1602 - PCM Not Programmed. 3. An updated calibration or software release is available for either the PCM or TCM ECUs. This procedure assumes that the wiTECH(TM) Vehicle Connection Interface (VCI) pod, StarSCAN(R) and StarMOBILE(R) devices are configured to your dealership's network with either a wired or wireless connection. The wiTECH(TM) VCI pod, StarSCAN(R) and StarMOBILE(R) must also be running at the latest operating system and software release level. For more help on how to network your StarSCAN(R) or StarMOBILE(R) reference the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the Download Center. For the wiTECH(TM) VCI pod use the "HELP" tab in the wiTECH(TM) Diagnostic Application. Table of contents 1. SECTION 1 - PCM / TCM FLASH PROCEDURE SECTION 1 - PCM / TCM FLASH PROCEDURE 2. REQUIRED TOOLS/EQUIPMENT REQUIRED TOOLS/EQUIPMENT: 3. TECH TIPS and INFORMATION TECH TIPS and INFORMATION: 4. PARTS REQUIRED PARTS REQUIRED Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2957 SECTION 1 - PCM / TCM FLASH PROCEDURE If using StarSCAN(R) or StarMOBILE(R) Desktop Client. Go To REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client If using StarMOBILE(R) Standalone Diagnostic Mode. Go To REPAIR PROCEDURE wiTECH(TM) Diagnostic Application REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the StarSCAN(R) or StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power on the StarSCAN(R) or StarMOBILE(R). If the StarMOBILE(R) is being used, launch the StarMOBILE(R) Desktop Client and connect to the appropriate StarMOBILE(R) device. 4. Retrieve the old ECU part number. From the tool's Home screen, a. Select "ECU View" b. Select "PCM/ECM" c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the Flash PCM/ECM screen for later reference. 5. Program the ECU as follows: a. Using the StarSCAN(R) / StarMOBILE(R) at the Home screen, select "ECU View" b. Select "PCM/ECM" c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File" and follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 4e, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. g. Select "Download to Scantool" h. Once the download is complete, select "Close" and then "Back" i. Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. j. When the PCM/ECM update is complete, select "OK" k. Verify that the part number at the top of the Flash PCM/ECM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 6. Continue to SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced. 7. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See Section 3 SECTION 3 - AUTHORIZED MODIFICATION LABEL for details). REPAIR PROCEDURE - wiTECH(TM) Diagnostic Application NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the wiTECH(TM) Vehicle Connection Interface (VCI) pod to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Launch the wiTECH(TM) Diagnostic Application and connect to the appropriate wiTECH(TM) device. 4. From the wiTECH(TM) Diagnostic Application Home screen, a. Select "HELP" b. Select "HELP CONTENTS" c. Follow the correct "HELP TOPIC" for the ECU being programmed SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES NOTE: Find the PCM/TCM Type for the vehicle, read and write down the steps, and then go to the step by step instructions for additional information on how to perform these procedures. STEP-BY-STEP INSTRUCTIONS If an EDC16-U31 PCM/ECM (2.0L) was replaced, perform the following additional steps and/or routines: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2958 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Program Variant Code If an EDC16-C2 PCM/ECM (2.2L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. IMA Rapid Calibration Test - Only on 06 PT AND up 4. Injector Quantity Adjustment - Only on 06 PT AND up If an EDC16-CP31 (3.0L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Diesel Particulate Filter (Used) Learning 4. NOx Catalyst (New) Initialization 5. Injector Quantity Adjustment 6. IMA Rapid Calibration Test 7. Fuel Mean Value Adaptation Initialization 8. Exhaust Throttle Plate Adaptive Learn Position If an EDC16-CP31-2 (2.8L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Injector Quantity Adjustment 4. Program Variant Code 5. ECU Replacement With Value Transfer if the ECU to be replaced is still responsive 6. ECU Replacement Without Value Transfer - if the ECU to be replaced is NOT responsive 7. Fuel Mean Value Adaptation Initialization 8. IMA Rapid Calibration Test 9. Set Oil Dilution Mass Value If a CM849 PCM/ECM (5.9L) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped If a CM2100 PCM/ECM (6.7l) was replaced, perform the following additional steps and/or routines: 1. PCM/ECM Replaced - if WIN equipped 2. Check PCM/ECM VIN - if NOT WIN equipped 3. Enable / Disable Vehicle Features - need to enable features 4. Injector Quantity Adjustment 5. Reset Regenerative Filter Timers 6. Mobile DeSoot - NO Minimum Required Soot Load If an Asian TCM was replaced, perform the following additional steps and/or routines: If an EATX TCM was replaced, perform the following additional steps and/or routines: If an NGC3 TCM ONLY was replaced, perform the following additional steps and/or routines: If an NGC4 TCM ONLY was replaced, perform the following additional steps and/or routines: 1. Quicklearn If an EGS TCM was replaced, perform the following additional steps and/or routines: 1. Initialize EGS STEP-BY-STEP INSTRUCTIONS Check PCM/ECM VIN Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2959 From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Check PCM/ECM VIN" and follow the on screen instructions. - When complete, select "Finish" Diesel Particulate Filter (Used) Learning From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Diesel Particulate Filter (Used) Learning" and follow the on screen instructions. - When complete, select "Finish" ECU Replacement with Value Transfer From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "ECU Replacement with Value Transfer" and follow the on screen instructions. - When complete, select "Finish" ECU Replacement without Value Transfer From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "ECU Replacement without Value Transfer" and follow the on screen instructions. - When complete, select "Finish" Enable / Disable Vehicle Features From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Enable / Disable Vehicle Features" and follow the on screen instructions. - When complete, select "Finish" Exhaust Throttle Plate Adaptive Learn Position From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Exhaust Throttle Plate Adaptive Learn Position" and follow the on screen instructions. - When complete, select "Finish" Fuel Mean Value Adaptation Initialization From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Fuel Mean Value Adaptation Initialization" and follow the on screen instructions. - When complete, select "Finish" IMA Rapid Calibration From the "Home" screen, select "ECU View" Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2960 - Select "PCM/ECM" - Select "Misc. Functions" - Select "IMA Rapid Calibration Test" and follow the on screen instructions. - When complete, select "Finish" Initialize EGS From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Initialize EGS" and follow the on screen instructions. - When complete, select "Finish" Injector Quantity Adjustment From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Injector Quantity Adjustment" and follow the on screen instructions. - When complete, select "Finish" Mobile DeSoot - NO Minimum Required Soot Load From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Mobile DeSoot - NO Minimum Required Soot Load" and follow the on screen instructions. - When complete, select "Finish" NOx Catalyst (New) Initialization From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "NOx Catalyst (New) Initialization" and follow the on screen instructions. - When complete, select "Finish" PCM/ECM Replaced The vehicle pin (Personal Identification Number) will be required to complete the routine. This information may be obtained in three ways: 1. The original selling invoice 2. DealerCONNECT > Parts > Key Codes 3. Contacting the District Manager. From the "Home" screen, select "ECU View" - Select "WIN" - Select "Misc. Functions" - Select "PCM/ECM Replaced" and follow the on screen instructions. - When complete, select "Finish" Program Variant Code From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Program Variant Code" and follow the on screen instructions. - When complete, select "Finish" Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2961 Quicklearn From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Quicklearn" and follow the on screen instructions. - When complete, select "Finish" Reset Regenerative Filter Timers From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Reset Regenerative Filter Times" and follow the on screen instructions. - When complete, select "Finish" Set Oil Dilution Mass Value From the "Home" screen, select "ECU View" - Select "PCM/ECM" - Select "Misc. Functions" - Select "Set Oil Dilution Mass Value" and follow the on screen instructions. - When complete, select "Finish" SECTION 3 - AUTHORIZED MODIFICATION LABEL NOTE: The following step is required by law when reprogramming a PCM/ECM and/or TCM. Type the necessary information on the "Authorized Modification Label" and attach near the VECI label. 1. Powertrain Control / Transmission Control Module Part Numbers (Insert P/Ns) Used 2. Change Authority: TSB XX--XX 3. Dealer Code: XXXXX 4. Date: XX-XX-XX REQUIRED TOOLS/EQUIPMENT: TECH TIPS and INFORMATION: CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2962 1. The wiTECH(TM) Diagnostic Application is the preferred method for flashing any Chrysler vehicle ECU. For more information, training tutorials are available under the "HELP" tab in the wiTECH(TM) Diagnostic Application, under the 'Training Aids' link. 2. To use the StarMOBILE(R) in Pass-Through Mode requires that your StarMOBILE(R) is connected to the dealerships network via a wired or wireless connection. For more information on how to use the StarMOBILE in Pass-Through Mode see the StarMOBILE(R) training tutorials available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Training Aids' link, under the 'Training Aids' link. 3. If the flash process is interrupted or aborted, the flash should be restarted. 4. Due to the PCM/ECM / TCM programming procedure, a DTC may be set in other ECUs within the vehicle. Some DTCs may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 5. Do not allow the battery charger to time out or the charging rate to climb above 13.5 Volts during the flash process. 6. The StarSCAN(R) and StarMOBILE(R) diagnostic tools fully support Internet connectivity and must be configured for your dealership's network. For help on setting up your StarSCAN(R) / StarMOBILE(R) for the dealership's network, refer to the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the download center. 7. The operating software in the StarSCAN(R) and StarMOBILE(R) must be programmed with the latest software release level. The software level is visible in the blue header at the top of the StarSCAN(R) and StarMOBILE(R) Desktop Client screens. For instructions on how to update your scan tool, refer to the StarSCAN(R) / StarMOBILE(R) Software Update guide available on 'DealerCONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation', under the download center. PARTS REQUIRED Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2963 The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2964 If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2965 Engine Control Module: Removal and Replacement Powertrain Control Module - Removal REMOVAL USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. To avoid possible voltage spike damage to PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable. 2. Unlock and disconnect the electrical connectors from PCM. 3. Remove the air cleaner box. 4. Remove the three mounting bolts. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2966 5. Tip module out and remove from bracket. Powertrain Control Module - Installation INSTALLATION USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET. 1. Tip module into bracket. 2. Install three mounting bolts and tighten to 9 Nm (80 in. lbs.) torque. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2967 3. Check pins in electrical connectors for damage. Repair as necessary. 4. Connect electrical connectors and lock. 5. Install air cleaner box. 6. Connect negative battery cable. 7. Use the scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Main Relay is located in the Fuse/Relay block. Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2971 Main Relay (Computer/Fuel System): Diagrams Connector - (IN F/RB) RELAY-MAIN - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2976 Accelerator Pedal Position Sensor: Diagrams Connector - (BODY) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1/1 (Powertrain) 3 Way Camshaft Position Sensor: Diagrams Camshaft Position Sensor 1/1 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CAMSHAFT 1/1 POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1/1 (Powertrain) 3 Way > Page 2982 Camshaft Position Sensor: Diagrams Camshaft Position Sensor 1/2 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CAMSHAFT 1/2 POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Description DESCRIPTION The camshaft position sensors are mounted to the front and rear of the cylinder head. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description > Page 2985 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Operation OPERATION NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt output reference circuit. A ground for the sensor is provided through the sensor return circuit. The PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the camshaft position sensor. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal Front FRONT 1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor electrical connector. 2. Disconnect negative battery cable. 3. Disconnect electrical connector from camshaft position sensor. 4. Remove camshaft position sensor mounting screws. 5. Remove sensor. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 2988 1. Disconnect negative battery cable. 2. Disconnect electrical connector at sensor. 3. Remove nut retaining heat shield. 4. Pull heat shield out to uncover sensor. 5. Remove mounting bolt. 6. Remove sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 2989 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation Front FRONT 1. Lubricate sensor o-ring. 2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9 Nm (79.5 in. lbs.). 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install the negative battery cable. 5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical connector. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 2990 1. Lubricate sensor o-ring. 2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. 3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Carefully attach electrical connector to camshaft position sensor. Feel for positive lock (click). Installation at angle may damage the sensor pins. 5. Install heat shield onto mounting stud. 6. Install heat shield retaining nut and tighten. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 > Page 2995 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Coolant Temperature Sensor 2 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Engine Coolant Temperature Sensor 1 > Page 2996 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 1 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Engine Coolant Temperature Sensor 1 (Powertrain) 2 Way > Page 2999 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Coolant Temperature Sensor 2 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE 2 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3000 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. ENGINE COOLANT TEMPERATURE SENSOR WIRING OR CONNECTORS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3001 NOTE: Diagnose and repair any ECT circuit DTCs before proceeding with this test. NOTE: Allow the engine to cool to ambient temperature before proceeding. 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature sensor(s) and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Turn the ignition on. 5. Monitor the scan tool data relative to the sensor(s) and wiggle test the wiring and connectors. 6. Look for the data to change or for a DTC to set during the wiggle test. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. ENGINE COOLANT LEVEL AND CONDITION WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Check the engine coolant level and the condition of the engine coolant. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 3 3. THERMOSTAT WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. Using the appropriate service information, determine the proper opening temperature of the thermostat. 2. With the scan tool, read the Engine Coolant Temperature Sensor value for each sensor. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 3. Monitor the sensor values on the scan tool. 4. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: Each thermostat should open at the temperature specified. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3002 Tests/PCM Verification Test No - Go to 4 4. ENGINE COOLANT TEMPERATURE SENSOR NOTE: Allow the engine to cool to ambient temperature before proceeding. WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. 1. With the scan tool, read the Engine Coolant Temperature Sensor value for each sensor. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. 2. Monitor each sensor value on the scan tool and the actual coolant temperature with a thermometer. 3. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The sensor value transition should be smooth as the engine reaches operating temperature. The thermometer reading and the coolant temperature values on the scan tool should remain relatively close. Were any problems found? Yes - Go to 5. No - Test complete. 5. ECT SIGNAL CIRCUIT HIGH RESISTANCE NOTE: Perform this procedure for the sensor where erratic sensor values were detected in the previous test step. 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the ECT Signal circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 No - Repair the ECT Signal circuit for excessive resistance. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 3003 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the Sensor Ground circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. ENGINE COOLANT TEMPERATURE SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the Engine Coolant Temperature Sensor. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CRANKSHAFT POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The crankshaft position sensor mounts to the rear of the engine block near the transmission. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 3009 Crankshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor (2). The PCM determines which cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth and notches (1), including one long reference tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal REMOVAL The Crankshaft Position Sensor is in the rear of the engine block near the transmission. 1. Remove the engine cover (1). 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner body (1) See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 3012 4. Disengage the upstream O2 sensor wire harness retainer (1) and crankshaft position sensor wire harness retainer (2) from the heat shield (3). 5. Remove one nut (1) and two heat shield retaining bolts (2). 6. Remove heat shield (3). 7. Remove the crankshaft position sensor mounting bolt. 8. Remove sensor with the wire harness attached. 9. Unlock and disconnect the electrical connector from the crankshaft position sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 3013 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation INSTALLATION 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Using a twisting motion, install the crankshaft position sensor. 3. Install the crankshaft position sensor bolt. Tighten the bolt to 9 Nm (80 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 3014 5. Install the heat shield (3) with one nut (1) and two heat shield retaining bolts (2). 6. Install the upstream O2 sensor wire harness retainer (1) and crankshaft position sensor wire harness retainer (2) to the heat shield (3). 7. Install the air cleaner body (1) See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation 8. Connect the negative battery cable. 9. Install the engine cover (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Remove engine cover. 2. Disconnect and isolate negative batter cable. 3. Disconnect upstream DPF temperature sensor electrical connector. 4. Remove upstream DPF temperature sensor. 5. Disconnect downstream DPF temperature sensor electrical connector. 6. Remove downstream DPF temperature sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 3019 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Position DPF downstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 2. Connect downstream temperature sensor electrical connector. 3. Position DPF upstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 4. Connect upstream temperature sensor electrical connector. 5. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal Exhaust Pressure Sensor: Service and Repair Removal EXHAUST PRESSURE SENSOR 1. Disconnect and isolate negative battery cable. 2. Remove electrical connector at pressure differential sensor (2). 3. Remove upstream exhaust pressure tube (4) from catalytic converter 4. Remove downstream pressure tube (6) from catalytic converter. 5. Remove pressure differential sensor mounting bolt. 6. Remove pressure differential sensor (2) and tubing (7) from vehicle. 7. Remove tubing (7) from pressure differential sensor (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Pressure Sensor > Component Information > Service and Repair > Removal > Page 3024 Exhaust Pressure Sensor: Service and Repair Installation EXHAUST PRESSURE SENSOR 1. Install tubing (7) on pressure differential sensor (2). 2. Position pressure differential sensor (2) and tubing (7). 3. Install pressure differential sensor mounting bolt (3). Tighten to 10 Nm (89 in. lbs.). 4. Install downstream pressure tube (6) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.). 5. Install upstream pressure tube (4) into catalytic converter. Tighten the fitting to 10 Nm (89 in. lbs.) 6. Position electrical connector (1) into bracket. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3028 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way Fuel Level Sensor: Diagrams Fuel Pump Module (FWD) (Body) 4 Way Connector (FWD) - (BODY) 4 WAY MODULE-FUEL PUMP (FWD) - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way > Page 3031 Fuel Level Sensor: Diagrams Fuel Pump Module C1 (AWD) (Body) 5 Way Connector C1 (AWD) - (BODY) 5 WAY MODULE-FUEL PUMP (AWD) - (BODY) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way > Page 3032 Fuel Level Sensor: Diagrams Fuel Pump Module C2 (AWD) (Body) 2 Way Connector C2 (AWD) - (BODY) 2 WAY MODULE-FUEL PUMP (AWD) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Level Sensor: Description and Operation Fuel Pump Module - Description DESCRIPTION - FUEL PUMP MODULE The fuel pump module is located on the top left side of the fuel tank. The fuel pump module contains the following components: - Mounting flange - Electric fuel pump - Fuel pump reservoir - Inlet strainer - Fuel pressure regulator - Fuel level sending unit - Fuel filter The fuel level sending unit (3) is the only serviceable component of the fuel pump module. If the electric fuel pump, fuel pressure regulator or fuel filter requires service, the fuel pump module must be replaced as an assembly. DESCRIPTION The fuel pump module is installed in the top of the fuel tank. The fuel pump module contains the following: - Electric fuel pump - Fuel pump reservoir Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 3035 - Inlet strainer - Fuel pressure regulator - Fuel gauge sending unit - Fuel supply line connection - Fuel Filter NOTE: The fuel level sending unit is the only serviceable item. If the fuel pump, fuel pressure regulator or fuel filters need service, replace the fuel pump module as an assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 3036 Fuel Level Sensor: Description and Operation Fuel Pump Module - Operation OPERATION - FUEL PUMP MODULE An electric fuel pump is located within the fuel pump module. The electric fuel pump is a positive displacement, immersible pump with a permanent magnet electric motor capable of creating 860 kPa (125 psi) of operating pressure. The fuel pressure regulator limits fuel pressure to 400 kPa (58 psi). The fuel gauge is controlled by the instrument cluster circuit board based upon cluster programming and a hard wired input received by the cluster from the fuel level sending unit on the module in the fuel tank. The instrument cluster continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. This information is available to other vehicle control modules via the Controller Area Network (CAN) data bus. Fuel gauge diagnosis is conducted as part ofthe instrument cluster circuitry. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Level Sensor: Service and Repair Fuel Pump Module - Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. 1. Perform Fuel System Pressure Release procedure. See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair 2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose. 3. Remove the negative battery cable. 4. Remove the rear seat cushion. 5. Rear seat cushion loose. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3039 6. Remove plastic cover. 7. Clean top of tank to remove loose dirt and debris. 8. Use special tool #9340 to remove left side module lock ring. 9. Note the fuel pump location on the top of the fuel tank. NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3040 10. Pull module up out of fuel tank, make sure that you do not spill fuel inside of vehicle. 11. Drain fuel from fuel pump module. Do not spill fuel in interior of vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3041 Fuel Level Sensor: Service and Repair Fuel Pump Module - Installation INSTALLATION NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. 1. Wipe seal area of tank clean. Place a new seal between the tank threads and the pump module opening. 2. Install module. 3. Position fuel pump module in tank. Make sure the alignment tab lines up on the fuel tank and pump module for Gas or Diesel fuel tanks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3042 4. While holding the pump module in position, install lock ring and use special tool Spanner Wrench #9340 to tighten lock ring. 5. Install plastic cover. 6. Install rear cushion. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3043 7. Install the negative battery cable. 8. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. 9. Fill fuel tank with clean fuel. Use the Scan Tool to pressurize the system and check for leaks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3047 Intake Air Temperature Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-INTAKE AIR TEMPERATURE (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect electrical connector from sensor. 3. Remove the sensor clean air duct. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 3050 Intake Air Temperature Sensor: Service and Repair Installation INSTALLATION 1. Install inlet air temperature sensor into the clean air duct. 2. Connect electrical connector to sensor. 3. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3054 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3055 Knock Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-KNOCK (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor Removal Knock Sensor: Service and Repair Knock Sensor - Removal REMOVAL The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Disconnect the negative battery cable. 2. Remove the bolt holding the knock sensor. 3. Remove sensor with electrical connector attached. 4. Disconnect electrical connector from knock sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor Removal > Page 3058 5. Remove the knock sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor Removal > Page 3059 Knock Sensor: Service and Repair Knock Sensor - Installation INSTALLATION The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Attach electrical connector to knock sensor. 2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening effects knock sensor performance, possibly causing improper spark control. 3. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3063 Manifold Pressure/Vacuum Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-MAP (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Operation Manifold Pressure/Vacuum Sensor: Description and Operation Operation OPERATION The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 volt and full scale is 4.5 volt. For a pressure swing of 0 - 15 psi the voltage changes 4.0 volt. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key on. The difference between current and what it was at key on is manifold vacuum. During key On (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in your work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC1 transmissions only, via the PCI bus) - Idle speed - Decel fuel shutoff The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 88 kPa (26 in. Hg). Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 101 kPa (29.92 in. Hg). For every 30.5 meters (100 feet) of altitude barometric pressure drops.33 kPa (0.10 in. Hg). If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Operation > Page 3066 Manifold Pressure/Vacuum Sensor: Description and Operation Description DESCRIPTION The MAP sensor mounts to the intake manifold. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Page 3067 Manifold Pressure/Vacuum Sensor: Testing and Inspection CHECKING THE MAP SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. MAP SENSOR WIRING OR CONNECTORS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Page 3068 NOTE: Diagnose and repair any MAP Sensor circuit DTCs before proceeding with this test. NOTE: Diagnose and repair any sensor supply or system voltage DTCs before proceeding with this test. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Go to 2 2. MAP VACUUM/BAROMETRIC PRESSURE 1. With a scan tool, read the Barometric Pressure. NOTE: The Barometric Pressure should be approximately equal to the actual barometric pressure. If necessary, compare the Barometric Pressure value of the tested vehicle to the value of a known good vehicle of a similar make and model. 2. Connect a vacuum gauge to a manifold vacuum source. 3. Start the engine. NOTE: If engine will not idle, maintain a constant RPM above idle. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 4. With the scan tool, read the MAP Sensor vacuum. NOTE: The scan tool reading for MAP vacuum should be within 1" of the vacuum gauge reading. Were any problems found? Yes - Go to 4 No - Go to 3 3. MAP SENSOR VOLTAGE 1. With the scan tool, monitor the MAP Sensor signal voltage. 2. With the engine idling in neutral or park, snap the throttle. NOTE: The MAP Sensor signal voltage should change from below 2.0 volts at idle to above 3.5 volts at wide open throttle. Were any problems found? Yes - Go to 4 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Page 3069 No - Test complete. 4. (F856) 5 VOLT SUPPLY CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (F856) 5 Volt Supply circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 5 No - Repair the (F856) 5 Volt Supply circuit for excessive resistance. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 5. (K1) MAP SIGNAL CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K1) MAP Signal circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 6 No - Repair the (K1) MAP Signal circuit for excessive resistance. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 6. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis. 2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the MAP Sensor harness connector and by Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and Operation > Page 3070 probing the appropriate terminal of the special tool #8815. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 3. Start the engine. Is the voltage below 0.5 volts? Yes - Go to 7 No - Repair the (K900) Sensor Ground circuit for excessive resistance. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 7. MAP SENSOR 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the Powertrain Control Module (PCM). 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test No - Replace the MAP Sensor. - Perform the PCM Verification Test.See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect electrical connector from manifold absolute pressure (MAP) sensor. 3. Remove screw from MAP sensor. 4. Remove MAP sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 3073 Manifold Pressure/Vacuum Sensor: Service and Repair Installation INSTALLATION 1. Install manifold absolute pressure (MAP) sensor to intake manifold. 2. Tighten screw to 4.5 Nm (40 in. lbs.). 3. Connect electrical connector to sensor. 4. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page 3078 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Powertrain) 4 Way Oxygen Sensor: Diagrams Oxygen Sensor 1/1 (Powertrain) 4 Way Connector (GAS) - (POWERTRAIN) 4 WAY SENSOR-OXYGEN 1/1 (GAS) - (POWERTRAIN) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (Powertrain) 4 Way > Page 3081 Oxygen Sensor: Diagrams Oxygen Sensor 1/2 (Engine Compartment) 4 Way Connector (GAS) - (ENGINE COMPARTMENT) 4 WAY SENSOR-OXYGEN 1/2 (GAS) - (ENGINE COMPARTMENT) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3082 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description Oxygen Sensor: Description and Operation Description DESCRIPTION The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. The downstream heated oxygen sensor threads into the system depending on emission package. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description > Page 3085 Oxygen Sensor: Description and Operation Operation OPERATION Separate upstream and downstream grounds are used on the NGC vehicles (4 Cyl.). As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The O2 sensors produce a constant 2.5 volts on NGC vehicles, depending upon the oxygen content of the exhaust gas. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produce a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, which can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2 sensor's input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. The NGC Controller has a common ground for the heater in the O2S. 12 volts is supplied to the heater in the O2S by the NGC controller. Both the upstream and downstream O2 sensors for NGC are pulse width modulation (PWM). NOTE: When replacing an O2 Sensor, the PCM RAM memory must be cleared, either by disconnecting the PCM C-1 connector or momentarily disconnecting the Battery negative terminal. The NGC learns the characteristics of each O2 heater element and these old values should be cleared when installing a new O2 sensor. The customer may experience driveability issues if this is not performed. UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 2.5 to 3.5 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 2.5 volt. When there is a lesser amount of oxygen present (rich air-fuel mixture) the sensor produces a voltage as high as 3.5 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. This is also used to establish the upstream O2 goal voltage (switching point). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 3086 Oxygen Sensor: Testing and Inspection CHECKING THE OXYGEN SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. OXYGEN SENSOR, WIRING OR CONNECTORS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 3087 NOTE: Diagnose and repair any O2 sensor or rationality DTCs before proceeding with this test. NOTE: When performing this procedure as part of another diagnostic process, it may be necessary to repeat this test for all of the oxygen sensors on the vehicle. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen sensor and the Powertrain Control Module (PCM). 3. Look for any chafed, pierced, pinched or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the PCM VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. OXYGEN SENSOR VOLTAGE 1. Start the engine and allow it to reach normal operating temperature. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 2. With a scan tool, monitor all O2 Sensor voltage readings. Is the voltage switching between 2.5 and 3.4 volts for all O2 sensors? Yes - Go To 3 No - Go To 4 3. O2 SENSOR HEATER OPERATION 1. Turn the ignition off. NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0 volts. 2. Turn the ignition on. 3. With a scan tool, actuate the O2 Sensor heater. 4. With the scan tool, monitor O2 Sensor voltage for at least two minutes. Does the voltage stay above 4.5 volts? Yes - Go To 4 No - Test complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 3088 4. O2 SENSOR 1. Turn the ignition off. NOTE: Check for contaminants that may cause improper O2 Sensor operation, such as contaminated fuel, unapproved silicone, or evidence of oil or coolant. 2. Disconnect the O2 Sensor harness connector. 3. Turn the ignition on. 4. With a scan tool, monitor the O2 Sensor voltage. NOTE: The voltage should be approximately 5.0 volts with the connector disconnected. 5. Connect a jumper wire between the signal circuit and the return circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from 5.0 volts to 2.5 volts with the jumper wire in place. Is the O2 Sensor voltage displayed on the scan tool as described? Yes - Replace the O2 Sensor. - Perform the PCM VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 5 5. O2 SENSOR SIGNAL CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Signal circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor signal circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the PCM VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 6 6. O2 SENSOR RETURN CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Return circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor return circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the PCM VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 7 7. POWERTRAIN CONTROL MODULE (PCM) 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the O2 sensor and the PCM. 2. Look for any chafed, pierced, pinched or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Monitor the scan tool data relative to the components tested in this procedure and wiggle test the wiring and connectors. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 3089 5. Look for the data to change or for a DTC to set during the wiggle test. 6. Search for any Technical Service Bulletins (TSBs) that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Replace and program the Powertrain Control Module (PCM). - Perform the PCM VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal Oxygen Sensor: Service and Repair Removal 2.4L DOWNSTREAM OXYGEN SENSOR (1/2) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wires going into oxygen sensor. Damage to the oxygen sensor may occur. NOTE: Use an oxygen sensor (O2S) removal tool for this procedure. 1. Raise and support vehicle. 2. Disconnect O2S wire harness mounting clips from engine or body, if equipped. 3. Disconnect O2S pigtail harness connector (1) from engine wiring harness. 4. Remove O2S (3) from exhaust pipe (2). UPSTREAM OXYGEN SENSOR (1/1) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wires going into oxygen sensor. Damage to the oxygen Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3092 sensor may occur. NOTE: Use an oxygen sensor (O2S) removal tool for this procedure. 1. Raise and support vehicle. 2. Disconnect O2S wire harness mounting clips from engine or body, if equipped. 3. Disconnect O2S pigtail harness connector (1) from engine wiring harness. 4. Remove O2S (3) from maniverter (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3093 Oxygen Sensor: Service and Repair Installation 2.4L DOWNSTREAM OXYGEN SENSOR (1/2) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. CAUTION: When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted back to their original positions on engine or body to prevent mechanical damage to wiring. NOTE: Use an O2S removal tool for this procedure. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new O2S. 1. Install O2 sensor (3) to exhaust pipe (2). Tighten to 41 Nm (30 ft. lbs.). 2. Connect O2 sensor pigtail harness connector (1) to engine wiring harness. 3. Connect O2S wire harness mounting clips to engine or body, if equipped. UPSTREAM OXYGEN SENSOR (1/1) WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER(S) BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. FAILURE TO ALLOW ENGINE TO COOL BEFORE REMOVAL MAY RESULT IN PERSONAL INJURY CAUSED BY BURNS. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3094 CAUTION: When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted back to their original positions on engine or body to prevent mechanical damage to wiring. NOTE: Use an O2S removal tool for this procedure. Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new O2S. 1. Install O2 sensor (3) to maniverter (2). Tighten to 41 Nm (30 ft. lbs.). 2. Connect O2 sensor pigtail harness connector (1) to engine wiring harness. 3. Connect O2S wire harness mounting clips to engine or body, if equipped. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams Vehicle Speed Sensor: Diagrams Connector (GAS MTX) - (POWERTRAIN) 3 WAY SENSOR-VEHICLE SPEED (GAS MTX) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > Camshaft Position Solenoid 1/1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > Camshaft Position Solenoid 1/1 > Page 3102 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Diagrams > Camshaft Position Solenoid 1/1 (Powertrain) 2 Way Variable Valve Timing Solenoid: Diagrams Camshaft Position Solenoid 1/1 (Powertrain) 2 Way Connector - (POWERTRAIN) 2 WAY SOLENOID-CAMSHAFT 1/1 POSITION - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Diagrams > Camshaft Position Solenoid 1/1 (Powertrain) 2 Way > Page 3105 Variable Valve Timing Solenoid: Diagrams Camshaft Position Solenoid 1/2 (Powertrain) 2 Way Connector - (POWERTRAIN) 2 WAY SOLENOID-CAMSHAFT 1/2 POSITION - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Valve Timing Solenoid - Description Variable Valve Timing Solenoid: Description and Operation Variable Valve Timing Solenoid Description DESCRIPTION Variable valve timing solenoid assembly. The solenoid receives pulse width modulation signal and the current is controlled within 0 ma to 1000 ma. The spool position is controllable at any position to control supply of oil between the advance and retard ports. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Valve Timing Solenoid - Description > Page 3108 Variable Valve Timing Solenoid: Description and Operation Variable Valve Timing Solenoid Operation OPERATION There is both an Intake and an exhaust camshaft sensor on vehicles equipped with a World Engine. The variable valve timing system used on World Engines requires the exact position of both the intake and exhaust camshaft. The GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of the camshafts. Intake and exhaust phaser oil control valves are required on World Engine vehicles using variable valve timing. The oil valves direct oil to the Intake and exhaust phasers. Oil pressure in the phasers moves the camshafts to an advanced or retarded position. To resolve this inherent conflict between optimum high and low speed valve timing, the GPEC1 controlled engine uses a variable valve timing system. The variable valve timing system advances and retards valve timing by rotating the position of both the intake and exhaust camshafts. With this system, the intake valve opening can range from 80 to 120 crankshaft degrees after Top Dead Center. Likewise, the exhaust valve opening can range from 85 to 120 crankshaft degrees before Top Dead Center. This degree of flexibility provides many benefits, including: Improved Engine Performance, Increased Fuel Economy, Improved Idle Stability and Decreased Engine Emissions. In non operating condition, the camshaft stays in lockpin position of cam phases. This is 120 degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust camshaft. The variable valve timing system is electronically controlled and hydraulically operated. The GPEC1 receives information from many sensors to determine the optimum valve timing. It then pulse-width modulates oil control valves which direct oil to the cam phasers. The cam phasers use oil pressure to rotate the intake and exhaust camshafts. The rotation of the camshafts is referred to as cam phasing. Before the GPEC1 can begin commanding the camshaft phasing, several enabling conditions must be met: - The engine oil temperature must be at least -6.6°C (20°F) - The oil control valve coil temperature must be less than 140°C (284°F) - Engine speed must be at least 600 to 1000 rpm to achieve minimum oil pressure. - Battery voltage must be at least 10 volts - And there must be no camshaft or crankshaft sensor faults, engine timing faults, or oil control valve faults First we will examine variable valve timing enabling conditions, and then we will take a closer look at the inputs and outputs of the system: - Accelerator pedal position sensor - Oil temperature sensor - Map sensor - Intake cam sensor - Exhaust cam sensor - Crankshaft sensor - GPEC1 - Exhaust phaser oil control valve - Intake phaser oil control valve - Inputs - Engine control module - Outputs - Sensed battery voltage A minimum oil temperature is required to enable variable valve timing operation. Oil temperature and viscosity also have an impact on the operation of variable valve timing after start-up. Oil is used to control the movement of the camshafts. An incorrect oil viscosity could adversely affect the operation of the system or even render the system inoperative. It may even set a fault code. The accelerator pedal position sensor indicates how far the driver wants to open the throttle plate. The GPEC1 calculates an initial camshaft set point based on whether the accelerator pedal is at part throttle or wide open throttle. The MAP sensor provides information regarding engine load. Sensed battery voltage provides information regarding current system voltage. Sensed battery voltage must be at least 10 volts in order for the oil control valves to function properly. This information allows the GPEC1 to adjust camshaft timing to achieve the best fuel economy, the best engine performance or a combination of both. The hall-effect crankshaft sensor provides RPM information and determines when the number one piston is approaching Top Dead Center. The sensor generates a signal as the tone wheel, attached to the crankshaft, rotates. The tone wheel has 60 teeth minus two. When the gap, created by the missing teeth passes by the sensor, a signal is produced that indicates the number one piston is at Top Dead Center. The GPEC1 uses crankshaft sensor data along with camshaft data to determine the actual position of the camshaft. There are two hall-effect camshaft sensors on engines equipped with variable valve timing. The GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of the camshaft. The GPEC1 individually controls each valve. It sends a pulse width modulated signal to move a spool within the outer casing of the valve. Depending upon spool movement, oil is directed through the passages to advance or retard cam timing. The oil control valve also has a special cleaning strategy at Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Valve Timing Solenoid - Description > Page 3109 key-on. The cleaning strategy is known as "debris crush mode". At key-on the GPEC1 cycles the oil control valve on and off several (5) times to crush any debris in the oil control valve and prevent the spool valve from sticking. In non operating condition, the camshaft stays in lockpin position of cam phases. This is 120 degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust camshaft. There are two oil control valves. One valve directs oil to the intake cam phaser, the other valve directs oil to the exhaust cam phaser. The valves are designed and function in the same manner. The outer casing of each oil valve has five oil passages. A passage for pressurized supply oil. A passage to the advance chamber of the cam phaser. A passage to the retard chamber of the cam phaser. A passage for oil return from the advance chamber of the cam phaser. A passage for oil return from the retard chamber of the cam phaser. Oil flows through the passages and applies pressure to the cam phasers to change cam timing. There are two cam phasers. One phaser controls the position of the intake camshaft. The other phaser controls the position of the exhaust camshaft. The phasers consist of a sprocket, a rotor vane, and a housing or stator. The exhaust cam phaser also consists of a front bushing and spring. We will discuss the purpose and function of the bushing and spring later. The housing is bolted and permanently fixed to the camshaft sprocket, while the rotor vane is bolted and permanently fixed to the camshaft. With this design, any movement of the rotor vane in relation to the housing will also move the camshaft. The phaser and sprocket are serviced as an assembly. Camshaft and crankshaft sensors provide feedback to the GPEC1 regarding the actual position of the camshafts. The GPEC1 then compares the actual camshaft positioning with desired positioning. If the desired positioning is not achieved within a specified time, during the second key cycle a trouble code is set. There are six new diagnostic trouble codes available to help you determine if the control circuit from the GPEC1 to the oil control valve is intact and operating properly. The codes identify whether the control circuit is open, shorted to ground, or shorted to power. Three trouble codes are related to intake camshaft positioning, the other three codes are specific to exhaust camshaft positioning. The oil control valve contains both electrical and mechanical components. It is electrically controlled by the GPEC1. The electrical current that energizes the coil results in mechanical motion of the spool valve. It is possible to verify both the electrical and mechanical operation of the valve. The oil control valve consists of a coil that is energized to move a spool within an outer casing. The condition of the coil can be tested with a Digital Volt Ohmmeter or DVOM. With the DVOM set to measure resistance, check the coil for an open, a short to ground, or excessive resistance. The correct resistance value of the coil is between 6 and 8 ohms. The mechanical operation of the oil control valve can be tested using actuator commands on the scan tool. Remove the oil control valve, then navigate to the actuator menu and select the oil control valve. Use commands to activate the valve and watch as the spool valve moves back and forth inside the casing. Because the cam phasers are hydraulically operated by engine oil, the condition of the oil is very important. The oil must be of the correct viscosity, not obstructed by debris, to maintain correct pressure. Maintaining the correct oil viscosity is critical to the operation of the variable valve timing system. The wrong oil viscosity may cause the variable valve timing to malfunction and trouble codes to set. The correct oil viscosity for this system is 5W20. Oil must be clean, unobstructed and free to flow through the variable valve timing system. Oil could become obstructed in oil passages located in the cylinder head, cylinder block, or even in the oil screen. In the event oil flow is obstructed, further diagnosis or disassembly may be required to pin point the source of the obstruction. The variable valve timing system relies on oil pressure to advance or retard the position of the camshaft. Insufficient oil pressure will adversely affect the operation of variable valve timing. The minimum oil pressure for this system is 15 psi at normal operating temperature. Though not directly used to change camshaft positioning, the oil screen is an important component of the variable valve timing system. It helps to remove debris going to the variable valve timing components. The oil screen is located in the cylinder block, immediately below the cylinder head. Oil must pass through the oil screen before entering the oil control valve. The cylinder head must be removed to service the oil screen. The intention is not to service the oil screen during vehicle life. How the cam phaser works. The cam phaser assembly has eight separate chambers; four advance chambers and four retard chambers. When camshaft advance is requested, oil enters all four advance chambers and exerts force on the rotor vane. Because the rotor vane is bolted to the camshaft, the entire camshaft profile moves along with the rotor vane. At the same time, oil is forced out of the retard chambers. When camshaft retard is requested oil enters the retard chambers to move the camshaft in the opposite direction. There is a lock pin on one side of the rotor vane that fits inside a recessed area in the housing. The lock pin ensures that the default position of the intake cam phaser is 120 crankshaft degrees full retard and the default position of the exhaust cam phaser is 120 crankshaft degrees full advance. When the engine is turned off, rotational force and inertia move the intake camshaft and rotor vane toward the retard position. The exhaust cam phaser includes a spring and bushing to work against the rotational force of the engine, allowing the exhaust cam phaser to lock in the fully advanced position. Under most conditions the cam phasers are returned to lock pin position when the engine is turned off. In the unique condition of an engine stall, which abruptly shuts off the engine, the cam phasers may not return to the lock pin position. In this case, the phasers will return to the lock pin position at the next start-up. Lock pin position is the most ideal cam timing for idle stability. When engine rpm exceeds approximately 600 to 1000 rpm, oil pressure unlocks the pins and variable valve timing resumes. Once enabling conditions are met, the GPEC1 uses input from sensors to calculate optimum valve timing. There are four preprogrammed modes from which the GPEC1 bases initial valve timing. - Starting - Idle or Part throttle - Wide open throttle - Limp-in or Default From each preprogrammed mode, the GPEC1 adjusts valve timing based on operating conditions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation > Variable Valve Timing Solenoid - Description > Page 3110 GPEC1 has calculated optimum intake valve timing of 112 degrees after Top Dead Center and optimum exhaust valve timing of 97 degrees before Top Dead Center. The GPEC1 pulse width modulates the oil control valves to advance or retard the camshaft to their desired location. The spool valve inside the intake oil control valve is energized and moves to allow pressurized oil into the advance chambers of the intake cam phaser. At the same time, the spool valve inside the exhaust oil control valve is energized and moves to allow pressurized oil into the retard chambers of the exhaust cam phaser. Oil enters the advance chambers of the intake phaser and the retard chambers of the exhaust phaser. Oil pressure releases the lock pin from its locked position and pushes against the rotor vane. Both the rotor vanes are moved, advancing the intake camshaft and retarding the exhaust camshaft. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal Variable Valve Timing Solenoid: Service and Repair Variable Valve Timing Solenoid - Removal Front Solenoid 1/1 FRONT SOLENOID 1/1 1. Disconnect negative battery cable. 2. Remove engine cover. 3. Rotate hose clamp out of way. 4. Disconnect oil pressure sensor electrical connector. 5. Remove oil pressure sensor. 6. Disconnect variable valve timing solenoid electrical connector. 7. Remove variable valve timing solenoid mounting bolt. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 3113 8. Pull solenoid straight out of cylinder head. Rear Solenoid 1/2 REAR SOLENOID 1/2 1. Disconnect negative battery cable. 2. Remove engine cover. 3. Disconnect variable valve timing solenoid electrical connector. 4. Remove variable valve timing solenoid mounting bolt. 5. Pull solenoid straight out of cylinder head. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 3114 Variable Valve Timing Solenoid: Service and Repair Variable Valve Timing Solenoid - Installation Front Solenoid 1/1 FRONT SOLENOID 1/1 1. Solenoid for front location 1/1. Note mounting tab location is different between front and rear solenoids. 2. Install solenoid into cylinder head. 3. Install mounting bolt and tighten to 12 Nm (9 ft. lbs.). 4. Install oil pressure sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 3115 5. Connect electrical connector to oil pressure sensor. 6. Connect electrical connector to Variable valve timing solenoid. 7. Connect negative battery cable. 8. Install engine cover. Rear Solenoid 1/2 REAR SOLENOID 1/2 1. Rear variable valve timing solenoid. Note mounting tab location is different between front and rear solenoids. 2. Install solenoid into cylinder head. 3. Install mounting bolt and tighten to 12 Nm (9 ft. lbs.). 4. Connect electrical connector to Variable valve timing solenoid. 5. Connect negative battery cable. 6. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams Vehicle Speed Sensor: Diagrams Connector (GAS MTX) - (POWERTRAIN) 3 WAY SENSOR-VEHICLE SPEED (GAS MTX) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Diagrams > Secondary Air Pump Assembly C1 4 Way Air Injection Pump: Diagrams Secondary Air Pump Assembly C1 4 Way Connector C1 - 4 WAY ASSEMBLY SECONDARY AIR PUMP - 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Diagrams > Secondary Air Pump Assembly C1 4 Way > Page 3125 Air Injection Pump: Diagrams Secondary Air Pump Assembly C2 2 Way Connector C2 - 2 WAY ASSEMBLY SECONDARY AIR PUMP - 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Remove engine cover. 2. Disconnect and isolate negative batter cable. 3. Disconnect upstream DPF temperature sensor electrical connector. 4. Remove upstream DPF temperature sensor. 5. Disconnect downstream DPF temperature sensor electrical connector. 6. Remove downstream DPF temperature sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 3131 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Position DPF downstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 2. Connect downstream temperature sensor electrical connector. 3. Position DPF upstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 4. Connect upstream temperature sensor electrical connector. 5. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3136 Canister Purge Solenoid: Diagrams Connector - (ENGINE COMPARTMENT) 2 WAY SOLENOID-EVAP PURGE - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Description and Operation > Description Canister Purge Solenoid: Description and Operation Description DESCRIPTION The vehicle uses a Linear Purge Valve. The linear purge valve is a solenoid that regulates the rate of vapor flow from the EVAP canister to the intake manifold. The PCM operates the linear purge valve. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Description and Operation > Description > Page 3139 Canister Purge Solenoid: Description and Operation Operation OPERATION All vehicles use a linear purge valve. The linear purge valve is a solenoid that regulates the rate of vapor flow from the evaporative emission (EVAP) canister to the intake manifold. The powertrain control module (PCM) operates the linear purge valve. During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. The linear purge valve operates at a frequency of 200 hz and is controlled by an engine controller circuit that senses the current being applied to the linear purge valve and then adjusts that current to achieve the desired purge flow. The linear purge valve controls the purge rate of fuel vapors from the vapor canister and fuel tank to the engine intake manifold. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Removal Canister Purge Solenoid: Service and Repair Removal REMOVAL 1. Disconnect and isolate negative battery cable at battery. 2. Disconnect electrical connector (4) from evaporator purge solenoid (1). 3. Remove purge hose (3) from evaporator purge solenoid (1). 4. Remove quick connect fuel tank hose (2) from evaporator purge solenoid (1). 5. Release tab to remove evaporator purge solenoid (1) from body bracket (5). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Removal > Page 3142 Canister Purge Solenoid: Service and Repair Installation INSTALLATION 1. Install evaporator purge solenoid (1) to body bracket (5). Make sure the tab secures the solenoid to the bracket. 2. Install quick connect fuel tank hose (2) to evaporator purge solenoid (1). 3. Install purge hose (3) to evaporator purge solenoid (1). 4. Connect electrical connector (4) to evaporator purge solenoid (1). 5. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal Evaporative Emission Control Canister: Service and Repair Removal REMOVAL 1. Disconnect negative battery cable. 2. Raise and support vehicle. 3. Depress locking tab on vapor hose connector and pull off of canister. 4. Remove hose from ESIM module. 5. Vapor hose removed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 3147 6. Disconnect the electrical connector from ESIM module. 7. Remove two vapor canister mounting bolts. 8. Remove assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 3148 Evaporative Emission Control Canister: Service and Repair Installation INSTALLATION 1. Install canister and bracket. 2. Connect filter hose to ESIM. 3. Connect vapor hose. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 3149 4. Make sure locking tab on hose connector locks in place. 5. Connect electrical connector to ESIM module. 6. Lower vehicle. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 3153 Leak Detector: Diagrams Connector (EXCEPT EXPORT) - (BODY/DIFFERENTIAL VENT JUMPER) 2 WAY SWITCH-EVAP SYSTEM MONITOR (EXCEPT EXPORT) - (BODY/DIFFERENTIAL VENT JUMPER) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 3154 Leak Detector: Description and Operation OPERATION SYSTEM The ESIM (Evaporative System Integrity Monitor) is very similar to the NVLD. However, the design of the ESIM has been simplified and unlike the NVLD the ESIM does not require a solenoid. The ESIM mounts directly to the canister, eliminating the need for a mounting bracket. It is critical that the ESIM is mounted vertically. On vehicles where the canister is mounted on an angle, the ESIM requires an adaptor to maintain a vertical position. When the ESIM is installed vertically, the electrical connector is in the 3 o'clock position. EXPLODED VIEW Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 3155 The ESIM assembly consists of a housing, a small weight and a large weight that serve as check valves, a diaphragm, a switch and a cover. There is one large weight and one small weight check valve in the ESIM assembly. A seal is attached at the end of each weighted check valve. The large weight check valve seals for pressure. The small weight check valve seals for vacuum. The weighted check valves are contained within the ESIM housing. CUT AWAY OF MODULE The ESIM (Evaporative System Integrity Monitor), while physically different than the NVLD system, performs the same basic function as the NVLD does - controlling evaporative emissions. The ESIM has been simplified because the solenoid used on the NVLD is not used on the ESIM. The ESIM consists of housing, two check valves (sometimes referred to as weights), a diaphragm, a switch and a cover. The larger check valve seals for pressure and the smaller one seals for vacuum. During refueling, pressure is built up in the evaporative system. When pressure reaches approximately.5 inches of water, the large check valve unseats and pressure vents to the fresh air filter. Conversely, when the system cools and the resulting vacuum lifts the small check valve from its seat and allows fresh air to enter the system and relieve the vacuum condition. When a calibrated amount of vacuum is achieved in the evaporative system, the diaphragm is pulled inward, pushing on the spring and closing the contacts. The ESIM conducts test on the evaporative system as follows: An engine off, non-intrusive test for small leaks and an engine running, intrusive test for medium/large leaks. The ESIM weights seal the evap. system during engine off conditions. If the evap. system is sealed, it will be pulled into a vacuum, either due to the cool down from operating temperature or diurnal ambient temperature cycling. When the vacuum in the system exceeds about 1" H20, the vacuum switch closes. The switch closure sends a signal to the GPEC1. In order to pass the non-intrusive small leak test, the ESIM switch must close within a calculated amount of time and within a specified amount of key-off events. If the ESIM switch does not close as specified, the test is considered inconclusive and the intrusive engine running test will be run during the next key-on cycle. This intrusive test will run on the next cold engine running condition. Conditions for running the intrusive test are: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 3156 - After the vehicle is started, the engine coolant temperature must be within 10° C (50°F) of ambient to indicate a cold start. - The fuel level must be between 12% and 88%. - The engine must be in closed loop. - Manifold vacuum must be greater than a minimum specified value. - Ambient temperature must be between 4° C and 37° C (39° F and 98° F)and the elevation level must be below 8500 feet. The test is accomplished by the GPEC1 activating the purge solenoid to create a vacuum in the evaporative system. The GPEC1 then measures the amount of time it takes for the vacuum to dissipate. This is known as the vacuum decay method. If the switch opens quickly a large leak is recorded. If the switch opens after a predetermined amount of time, then the small leak matures. If the switch does not close, then a general evaporative failure is recorded. The purge monitor tests the integrity of the hose attached between the purge valve and throttle body/intake. The purge monitor is a two stage test and it runs only after the evaporative system passes the small leak test. Even when all of the thresholds are met, a small leak won't be recorded until after the medium/large leak monitor has been run. This is accomplished by the GPEC1 activating the purge solenoid to create a vacuum in the evaporative system. The GPEC1 then measures the amount of time it takes for the vacuum to dissipate. This is known as the vacuum decay method. If the switch opens quickly a large leak is recorded. If the switch opens after a predetermined amount of time, then the small leak matures. If the medium/large leak test runs and the ESIM switch doesn't close, a general evaporative test is run. The purge solenoid is activated for approximately 10 seconds, increasing the amount of vacuum in the system. IF the ESIM switch closes after the extended purge activation, a large leak fault is generated. If the switch doesn't close, a general evaporative system fault is generated. The purge monitor tests the integrity of the hose attached between the purge valve and throttle body/intake. The purge monitor is a two stage test and it runs only after the evaporative system passes the small leak test. Stage one of the purge monitor is non-intrusive. GPEC1 monitors the purge vapor ratio. If the ratio is above a calibrated specification, the monitor passes. Stage two is an intrusive test and it runs only if stage one fails. During the stage two test, the GPEC commands the purge solenoid to flow at a specified rate to force the purge vapor ratio to update. The vapor ratio is compared to a calibrated specification and if it is less than specified, a one-trip failure is recorded. The ESIM switch stuck closed monitor checks to see if the switch is stuck closed. This is a power down test that runs at key-off; when the GPEC1 sees 0 rpm's, the purge solenoid is energized for a maximum of 30 seconds, venting any vacuum trapped in the evaporative system. If the switch opens or was open before the test began, the monitor passes. If the switch doesn't open, the monitor fails. This is a two-trip MIL. The star scan tool can be used to force the ESIM switch stick closed monitor to run. The GPEC1 also uses the ESIM to detect a loose or missing gas cap. The GPEC1 controller looks for a change in the fuel level (25% minimum) and then gas cap is loose or missing. If a medium/large leak is detected, a loose gas cap light illuminates and a pending one-trip fault code is set. On the GPEC1, this is a three-trip fault before the code matures Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Description and Operation EGR Cooler: Description and Operation DESCRIPTION The EGR cooler (7) cools recirculated exhaust gasses to reduce combustion temperature and a greater mass of exhaust gases can thus be circulated. There is less nitrogen oxides as a result. The EGR cooler (7) allows the engine and catalytic converter to reach their operating temperature quickly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > EGR Cooler - Removal EGR Cooler: Service and Repair EGR Cooler - Removal REMOVAL 1. Remove engine cover . See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Cover - Removal 2. Drain cooling system . See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining 3. Remove EGR cooler coolant hoses (8). 4. Remove EGR cooler to exhaust manifold tube (11). 5. Remove EGR cooler to EGR valve tube (1). 6. Remove EGR cooler mounting nuts (6). 7. Remove EGR cooler (7). 8. Remove the bypass valve mounting screws (3). 9. Separate the bypass valve assembly from the EGR cooler body (5). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > EGR Cooler - Removal > Page 3163 EGR Cooler: Service and Repair EGR Cooler - Installation INSTALLATION 1. Using a new gasket, position the bypass valve assembly to the EGR cooler body (5). Tighten screws to 10 Nm (88 in. lbs.). 2. Position EGR cooler (7) and install mounting screws. Tighten to 10 Nm (88 in. lbs.). 3. Install EGR cooler to exhaust manifold tube (11). Tighten bolts to 20 Nm (14 ft. lbs.) and nuts to 20 Nm (14 ft. lbs.). 4. Install EGR cooler to EGR valve tube (1). Tighten bolts to 20 Nm (14 ft. lbs.). 5. Install coolant hoses. 6. Install vacuum line. 7. Fill cooling system . See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Filling 8. Install engine cover . See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Cover - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations It threads into the valve cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Description and Operation > Positive Crankcase Ventilation (PCV) Valve - Description Positive Crankcase Ventilation Valve: Description and Operation Positive Crankcase Ventilation (PCV) Valve - Description DESCRIPTION It threads into the valve cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Description and Operation > Positive Crankcase Ventilation (PCV) Valve - Description > Page 3170 Positive Crankcase Ventilation Valve: Description and Operation Positive Crankcase Ventilation (PCV) Valve - Operation OPERATION When the engine is not operating or during an engine backfire, the spring forces the plunger back against the seat. This prevents vapors from flowing through the valve. When the engine is at idle or cruising, high manifold vacuum is present. At these times manifold vacuum is able to completely compress the spring and pull the plunger to the top of the valve. In this position there is minimal vapor flow through the valve. During periods of moderate intake manifold vacuum the plunger is only pulled part way back from the inlet. This results in maximum vapor flow through the valve. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Description and Operation > Page 3171 Positive Crankcase Ventilation Valve: Testing and Inspection PCV SYSTEM WARNING: apply parking brake and/or block wheels before performing any test or adjustment with the engine operating. 1. With engine idling, remove the hose from the PCV valve. If the valve is not plugged, a hissing noise will be heard as air passes through the valve. A strong vacuum should also be felt when a finger is placed over the valve inlet. 2. Install hose on PCV valve. Remove the make-up air hose from the air plenum at the rear of the engine. Hold a piece of stiff paper (parts tag) loosely over the end of the make-up air hose. 3. After allowing approximately one minute for crankcase pressure to reduce, the paper should draw up against the hose with noticeable force. If the engine does not draw the paper against the grommet after installing a new valve, replace the PCV valve hose. 4. Turn the engine off. Remove the PCV valve from intake manifold. The valve should rattle when shaken. 5. Replace the PCV valve and retest the system if it does not operate as described in the preceding tests. Do not attempt to clean the old PCV valve. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Positive Crankcase Ventilation (PCV) Valve - Removal Positive Crankcase Ventilation Valve: Service and Repair Positive Crankcase Ventilation (PCV) Valve - Removal REMOVAL 1. Remove the engine cover. 2. Remove the hose from the PCV valve. 3. Unscrew the PCV valve. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Positive Crankcase Ventilation (PCV) Valve - Removal > Page 3174 Positive Crankcase Ventilation Valve: Service and Repair Positive Crankcase Ventilation (PCV) Valve - Installation INSTALLATION 1. Lubricate the O-ring on the valve. 2. Install the PCV valve and tighten the valve to 8.1 Nm (72 in. lbs.). 3. Install the hose. 4. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal Exhaust Temperature Sensor: Service and Repair Removal REMOVAL 1. Remove engine cover. 2. Disconnect and isolate negative batter cable. 3. Disconnect upstream DPF temperature sensor electrical connector. 4. Remove upstream DPF temperature sensor. 5. Disconnect downstream DPF temperature sensor electrical connector. 6. Remove downstream DPF temperature sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Removal > Page 3180 Exhaust Temperature Sensor: Service and Repair Installation INSTALLATION 1. Position DPF downstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 2. Connect downstream temperature sensor electrical connector. 3. Position DPF upstream temperature sensor into DPF. Tighten to 25 Nm (221 in. lbs.). 4. Connect upstream temperature sensor electrical connector. 5. Install engine cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System Fuel Pressure: Testing and Inspection Checking the Fuel Delivery System CHECKING THE FUEL DELIVERY SYSTEM For a complete wiring diagram, refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. CHECKING THE FUEL PUMP OPERATION 1. Turn the ignition on. NOTE: Diagnose and repair any fuel pump control circuit or relay DTCs before continuing with this test. 2. With a scan tool, actuate the fuel pump control to ON (100%). NOTE: It may be necessary to use a mechanics stethoscope in the next step. 3. Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly, without excessive noise. If necessary, compare to a known good vehicle of similar year, make, and model. NOTE: If the pump has excessive noise or grinding, the pump should be replaced. CAUTION: Stop all actuation tests before continuing. Is the fuel pump operating when actuated? Yes - Go To 2 No - Go To 7 2. CHECKING THE FUEL PRESSURE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Install a fuel pressure gauge on the fuel rail. 3. Turn the ignition on. 4. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: Non SRT fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). CAUTION: Stop all actuation tests before continuing. Select the conclusion that best matches the result of the test: Fuel pressure is within the stated specification - Test complete. Fuel pressure is below the stated specification - Go To 3 Fuel pressure is above the stated specification - Replace the fuel filter/pressure regulator. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 3. RESTRICTED FUEL SUPPLY LINE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3187 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. 3. Install special 5/16 fuel line adapter tool #6539 between disconnected fuel line and the fuel pump module. 4. Attach a fuel pressure test gauge to the T fitting on tool #6539. 5. Turn the ignition on. 6. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: Non SRT fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). CAUTION: Stop all actuation tests before proceeding. Is the fuel pressure within specification? Yes - Repair or replace fuel supply line as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 4 4. SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes - Go To 5 No - Go To 6 5. FUEL TANK SIPHON HOSE OR FUEL LINE RESTRICTED OR DAMAGED 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Gain access to the fuel pump module and the fuel tank module. 3. Inspect the fuel line and siphon hose between the fuel pump module and the fuel tank module. Look for disconnected or damaged lines and hoses. 4. Inspect the fuel pressure regulator for damage or a condition that might cause a fuel flow problem. Make sure that it is seated in the module properly. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 6 6. FUEL PUMP INLET STRAINER 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3188 WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Remove the fuel pump module and inspect the fuel inlet strainer for damage or a condition that might cause a fuel flow problem. Were any problems found? Yes - Replace the Fuel Pump Inlet Strainer. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. 7. FUEL PUMP GROUND CIRCUIT OPEN OR HIGH RESISTANCE 1. Turn the ignition off. 2. Disconnect the Fuel Pump Module harness connector. 3. Using a 12-volt test light connected to 12 volts, check the Fuel Pump Motor Ground circuit at the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Repair the Fuel Pump Ground circuit for an open circuit or high resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3189 Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down FUEL PRESSURE LEAK DOWN For a complete wiring diagram, refer to the Wiring Information. See: Diagrams/Electrical Diagrams WARNING: Follow these safety precautions to reduce the risk of fire and serious possible serious or fatal injury when performing this test procedure. Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. Use extreme caution when connecting and disconnecting fuel lines. - Considerable fuel leakage may occur when servicing the fuel system. Wear protective eye wear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair / replace as necessary. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3190 WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from Gas and Diesel Fuel Pressure/Decay Tester 8978. Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly Fuel Inlet Hose 8978-1 (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect the Reservoir Assembly 534960 (4) to the Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3191 - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 2. Turn the ignition on, wait five seconds, turn the ignition off and then wait 1 minute before proceeding. 3. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT-4 fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the Checking The Fuel Delivery System diagnostic procedure as directed. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System 5. CHECK FUEL DELIVERY SYSTEM FOR LEAK DOWN WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Close the Fuel System Isolation Valve (1) and then wait five minutes before proceeding. 2. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge (1) - Replace the fuel pump module. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Yes - On Fuel Outlet Gauge (2) - Replace the leaking fuel injector(s). - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - If directed here by another test, return to that test. Otherwise, test complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove lower rear seat cushion. 2. Remove the fuel pump module cover. 3. Disconnect the electrical connector for fuel pump module. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. Turn ignition key to OFF position. 7. Disconnect negative battery cable. 8. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory. The scan tool must be used to erase a DTC. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Removal Accelerator Pedal: Service and Repair Removal REMOVAL 1. Disconnect and isolate negative battery cable at battery. 2. Disconnect the electrical connector from accelerator pedal. 3. Remove mounting nuts and remove accelerator pedal from the mounting studs. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Removal > Page 3199 Accelerator Pedal: Service and Repair Installation INSTALLATION CAUTION: The accelerator pedal and mounting nuts need to be torque in a mandatory torque sequence or damage could result to the pedal assembly. 1. Install the accelerator pedal and mounting nuts to the mounting studs. Tighten the nuts in a mandatory torque sequence to 16 Nm (12 ft. lbs.). 2. Connect the electrical connector from accelerator pedal. 3. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). 4. Use a scan tool and perform the APPS RELEARN function. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3203 Accelerator Pedal Position Sensor: Diagrams Connector - (BODY) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal Air Filter Element: Service and Repair Air Cleaner - Removal REMOVAL 1. Turn lock retainers (5) and remove fresh air inlet (2) from air cleaner housing (1). 2. Disconnect intake air temperature sensor connector (4). 3. Remove air inlet tube (5) from air cleaner housing (1). 4. Unfasten clasps (2) on sides of air cleaner housing cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 3209 5. Pull air cleaner cover (1) aside. 6. Remove filter element (3). 7. If necessary, clean the inside of the air cleaner housing (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 3210 Air Filter Element: Service and Repair Air Cleaner - Installation INSTALLATION 1. Install new filter element. 2. Place cover over air cleaner housing. Snap clasps (2) in place. 3. Install air inlet tube (5). 4. Connect intake air temperature sensor connector (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 3211 5. Install fresh air inlet (2) on air cleaner housing (1) and lock retainers (5). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Description and Operation Fuel: Description and Operation FUEL REQUIREMENTS Your engine is designed to meet all emissions regulations and provide excellent fuel economy and performance when using high quality unleaded gasoline having an octane rating of 87. The use of premium gasoline is not recommended. The use of premium gasoline will provide no benefit over high quality regular gasoline, and in some circumstances may result in poorer performance. Light spark knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and immediate service is required. Engine damage resulting from operation with a heavy spark knock may not be covered by the new vehicle warranty. Poor quality gasoline can cause problems such as hard starting, stalling and hesitations. If you experience these symptoms, try another brand of gasoline before considering service for the vehicle. Over 40 auto manufacturers world-wide have issued and endorsed consistent gasoline specifications (the Worldwide Fuel Charter, WWFC) to define fuel properties necessary to deliver enhanced emissions, performance and durability for your vehicle. We recommend the use of gasolines that meet the WWFC specifications if they are available. REFORMULATED GASOLINE Many areas of the country require the use of cleaner burning gasoline referred to as "reformulated" gasoline. Reformulated gasoline contain oxygenates, and are specifically blended to reduce vehicle emissions and improve air quality. We strongly support the use of reformulated gasoline. Properly blended reformulated gasoline will provide excellent performance and durability for the engine and fuel system components. GASOLINE/OXYGENATE BLENDS Some fuel suppliers blend unleaded gasoline with oxygenates such as 10% ethanol, MTBE, and ETBE. Oxygenates are required in some areas of the country during the winter months to reduce carbon monoxide emissions. Fuels blended with these oxygenates may be used in your vehicle. CAUTION: DO NOT use gasoline containing METHANOL. Gasoline containing methanol may damage critical fuel system components. MMT IN GASOLINE MMT is a manganese-containing metallic additive that is blended into some gasoline to increase octane. Gasolines blended with MMT provide no performance advantage beyond gasoline of the same octane number without MMT. Gasolines blended with MMT reduce spark plug life and reduce emission system performance in some vehicles. We recommend that gasoline free of MMT be used in your vehicle. The MMT content of gasoline may not be indicated on the gasoline pump; therefore, you should ask your gasoline retailer whether or not his/her gasoline contains MMT. It is even more important to look for gasoline without MMT in Canada because MMT can be used at levels higher than allowed in the United States. MMT is prohibited in Federal and California reformulated gasoline. SULFUR IN GASOLINE If you live in the northeast United States, your vehicle may have been designed to meet California low emission standards with Cleaner-Burning California reformulated gasoline with low sulfur. If such fuels are not available in states adopting California emission standards, your vehicles will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be adversely affected. Gasoline sold outside of California is permitted to have higher sulfur levels which may affect the performance of the vehicle's catalytic converter. This may cause the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light to illuminate. We recommend that you try a different brand of unleaded gasoline having lower sulfur to determine if the problem is fuel related prior to returning your vehicle to an authorized dealer for service. CAUTION: If the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light is flashing, immediate service is required. MATERIALS ADDED TO FUEL All gasoline sold in the United States and Canada is required to contain effective detergent additives. Use of additional detergents or other additives is not needed under normal conditions. FUEL SYSTEM CAUTIONS CAUTION: Follow these guidelines to maintain your vehicle's performance: - The use of leaded gas is prohibited by Federal law. Using leaded gasoline can impair engine performance, damage the emission control system, and could result in loss of warranty coverage. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Description and Operation > Page 3215 - An out-of-tune engine, or certain fuel or ignition malfunctions, can cause the catalytic converter to overheat. If you notice a pungent burning odor or some light smoke, your engine may be out of tune or malfunctioning and may require immediate service. Contact your dealer for service assistance. - When pulling a heavy load or driving a fully loaded vehicle when the humidity is low and the temperature is high, use a premium unleaded fuel to help prevent spark knock. If spark knock persists, lighten the load, or engine piston damage may result. - The use of fuel additives which are now being sold as octane enhancers is not recommended. Most of these products contain high concentrations of methanol. Fuel system damage or vehicle performance problems resulting from the use of such fuels or additives is not the responsibility of Chrysler Corporation and may not be covered under the new vehicle warranty. NOTE: Intentional tampering with emissions control systems can result in civil penalties being assessed against you. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Description Fuel Filler Cap: Description and Operation Description DESCRIPTION The plastic fuel fill cap is threaded/quarter turn onto the end of the fuel filler tube. It's purpose is to retain vapors and fuel in the fuel tank. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Description > Page 3220 Fuel Filler Cap: Description and Operation Operation OPERATION The loss of any fuel vapor out of fuel filler tube is prevented by the use of pressure-vacuum fuel fill cap. Relief valves inside the cap will release fuel tank pressure at predetermined pressures. Fuel tank vacuum will also be released at predetermined values. This cap must be replaced by a similar unit if replacement is necessary. This is in order for the system to remain effective. CAUTION: Remove fill cap before servicing any fuel system component to relieve tank pressure. If the cap is left loose, a Diagnostic Trouble Code (DTC) may be set. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1. Remove lower rear seat cushion. 2. Remove the fuel pump module cover. 3. Disconnect the electrical connector for fuel pump module. 4. Start and run engine until it stalls. 5. Attempt restarting engine until it will no longer run. 6. Turn ignition key to OFF position. 7. Disconnect negative battery cable. 8. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory. The scan tool must be used to erase a DTC. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (Powertrain) 2 Way Fuel Injector: Diagrams Fuel Injector 1 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY INJECTOR-FUEL 1 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (Powertrain) 2 Way > Page 3229 Fuel Injector: Diagrams Fuel Injector 2 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY INJECTOR-FUEL 2 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (Powertrain) 2 Way > Page 3230 Fuel Injector: Diagrams Fuel Injector 3 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY INJECTOR-FUEL 3 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (Powertrain) 2 Way > Page 3231 Fuel Injector: Diagrams Fuel Injector 4 (Powertrain) 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY INJECTOR-FUEL 4 (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Description Fuel Injector: Description and Operation Description DESCRIPTION The injectors are positioned in the intake manifold with the nozzle ends directly above the intake valve port. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Description > Page 3234 Fuel Injector: Description and Operation Operation OPERATION The fuel injectors are 12 volt electrical solenoids. The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a hollow cone or two streams. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. Fuel injectors are not interchangeable between engines. Injector operation is controlled by a ground path provided for each injector by the PCM. Injector on-time (pulse-width) is variable, and is determined by the PCM processing all the data previously discussed to obtain the optimum injector pulse width for each operating condition. The pulse width is controlled by the duration of the ground path provided. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures Fuel Injector: Procedures INJECTOR CONNECTOR 1. Disconnect electrical connectors at the fuel injectors. 2. To remove connector pull the red colored slider away from injector (1). While pulling the slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, make note of wiring location before removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 3237 Fuel Injector: Removal and Replacement Fuel Injector - Removal REMOVAL WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death. 1. Release the fuel pressure, refer to the fuel pressure release procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect the negative battery cable. 3. Disconnect the electrical connectors from the fuel injectors. 4. Fuel line connection at fuel rail. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 3238 5. Remove the fuel line from the fuel rail. 6. Remove wire harness from fuel rail mounting studs. 7. Remove the 2 bolts to the fuel rail at the lower manifold. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 3239 8. Remove the fuel rail. 9. Remove clip holding fuel injector to fuel rail. 10. Remove fuel injector clip and fuel injector from fuel rail. Fuel Injector - Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 3240 1. Apply a light coating of clean engine oil to the upper O-ring. 2. Install injector in cup on fuel rail. 3. Install retaining clip. 4. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector. 5. Insert fuel injector nozzles into openings in lower intake manifold. Seat the injectors in place. 6. Tighten fuel rail mounting screws to 27 Nm (20 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 3241 7. Install wiring harness clips to the fuel rail mounting studs. 8. Attach electrical connectors to fuel injectors, refer to the Fuel Injector Connector for electrical connector installation. 9. Connect fuel supply tube to fuel rail. 10. Connect the negative battery cable. 11. Use the scan tool to pressurize the fuel system. Check for leaks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair Fuel Line Coupler: Service and Repair QUICK-CONNECT FITTINGS Different types of quick-connect fittings are used to attach the various fuel system components, lines and tubes. These are: a single-button type, a two-button type, a pinch type, a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Some may require the use of a special tool for disconnection and removal. DISCONNECTING WARNING: The fuel system is under a constant pressure (even with engine off). Before servicing any fuel system hose, fitting or line, fuel system pressure must be released. See: Fuel Filter/Fuel Pressure Release/Service and Repair CAUTION: Before separating a quick-connect fitting, pay attention to what type of fitting is being used by referring to Quick-Connect Fitting Removal. This will prevent unnecessary fitting or fitting latch breakage. CAUTION: The interior components (O-rings, clips) of quick-connect fittings are not serviced separately, but new plastic spacers and latches are available for some types. If service parts are not available, do not attempt to repair the damaged fitting or fuel line (tube). If repair is necessary, replace the complete fuel line (tube) assembly. 1. Perform fuel pressure release procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect negative battery cable from battery. 3. Clean fitting of any foreign material before disassembly. 4. Single-Button Type Fitting: This type of fitting is equipped with a single push-button (2) located on the quick-connect fitting. 5. The push-button is attached to two internal latches (1). To disconnect, press on push-button with your thumb and unlatch fitting from fuel line. Special tools are not required for disconnection. DO NOT ATTEMPT TO PRY OR PULL UP ON PUSH-BUTTON. LATCHES WILL BE BROKEN. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3245 6. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 7. Disconnect negative battery cable from battery. 8. Clean fitting of any foreign material before disassembly. 9. 2-Button Type Fitting: This type of fitting (1) is equipped with a push-button located on each side of quick-connect fitting (2). Press on both buttons simultaneously for removal. Special tools are not required for disconnection. 10. Pinch-Type Fitting: This fitting (1) is equipped with two finger tabs (2). Pinch both tabs together while removing fitting. Special tools are not required for disconnection. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3246 11. Single-Tab Type Fitting: This type of fitting (3) is equipped with a single pull tab (1). The tab is removable. After tab is removed, quick-connect fitting can be separated from fuel system component. Special tools are not required for disconnection. 12. Press release tab on side of fitting to release pull tab (1). If release tab is not pressed prior to releasing pull tab, pull tab will be damaged. 13. While pressing release tab on side of fitting, use screwdriver (2) to pry up pull tab. 14. Raise pull tab until it separates from quick-connect fitting. 15. Two-Tab Type Fitting: This type of fitting (2) is equipped with tabs located on both sides of fitting (1). The tabs are supplied for disconnecting quick-connect fitting from component being serviced. a. To disconnect quick-connect fitting, squeeze plastic retainer tabs (1) against sides of quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. b. Pull fitting from fuel system component being serviced. c. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-rings and spacer will remain in quick-connect fitting connector body. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3247 16. Plastic Retainer Ring Type Fitting: This type of fitting can be identified by the use of a full-round plastic retainer ring (4) usually black in color. a. To release fuel system component from quick-connect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting (6). With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection. b. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body. c. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. 17. Latch Clips Type 1: Depending on vehicle model and engine, 2 different types of safety latch clips are used. Type-1 (4) is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/fuel rail connection, or to join fuel lines together. 18. Pry up on latch clip with a screwdriver (3). 19. Slide latch clip toward fuel rail while lifting with screwdriver. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3248 20. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (1). Use tool to release locking fingers in end of line. 21. With special tool still inserted, pull fuel line from fuel rail. 22. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 23. Disconnect quick-connect fitting from fuel system component being serviced. 24. Latch Clips Type 2: Depending on vehicle model and engine, 2 different types of safety latch clips are used. Type-1 is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/fuel rail connection, or to join fuel lines together. 25. Type 2: Separate and unlatch small arms on end of clip and swing away from fuel line. 26. Slide latch clip toward fuel rail while lifting with screwdriver. 27. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (1). Use tool to release locking fingers in end of line. 28. With special tool still inserted, pull fuel line from fuel rail. 29. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 30. Disconnect quick-connect fitting from fuel system component being serviced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Page 3249 31. Wing Type: A special tool is not necessary to disconnect this type of fitting (2). This line is used on different fuel and emission components. The graphic shows the fitting used on an EVAP canister. 32. Use two fingers to push on fitting wings (2) 33. Pull and disconnect fitting while holding wings. 34. After disconnection, locking fingers will remain within quick-connect fitting. CONNECTING 1. Inspect quick-connect fitting body and fuel system component for damage. Replace as necessary. 2. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 3. Insert quick-connect fitting into fuel tube or fuel system component until built-on stop on fuel tube or component rests against back of fitting. 4. Continue pushing until a click is felt. 5. Single-tab type fitting: Push new tab down until it locks into place in quick-connect fitting. 6. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 7. Latch Clip Equipped: Install latch clip (snaps into position). If latch clip will not fit, this indicates fuel line is not properly installed to fuel rail (or other fuel line). Recheck fuel line connection. 8. Connect negative cable to battery. 9. Start engine and check for leaks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System Fuel Pressure: Testing and Inspection Checking the Fuel Delivery System CHECKING THE FUEL DELIVERY SYSTEM For a complete wiring diagram, refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. CHECKING THE FUEL PUMP OPERATION 1. Turn the ignition on. NOTE: Diagnose and repair any fuel pump control circuit or relay DTCs before continuing with this test. 2. With a scan tool, actuate the fuel pump control to ON (100%). NOTE: It may be necessary to use a mechanics stethoscope in the next step. 3. Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly, without excessive noise. If necessary, compare to a known good vehicle of similar year, make, and model. NOTE: If the pump has excessive noise or grinding, the pump should be replaced. CAUTION: Stop all actuation tests before continuing. Is the fuel pump operating when actuated? Yes - Go To 2 No - Go To 7 2. CHECKING THE FUEL PRESSURE 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Install a fuel pressure gauge on the fuel rail. 3. Turn the ignition on. 4. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: Non SRT fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). CAUTION: Stop all actuation tests before continuing. Select the conclusion that best matches the result of the test: Fuel pressure is within the stated specification - Test complete. Fuel pressure is below the stated specification - Go To 3 Fuel pressure is above the stated specification - Replace the fuel filter/pressure regulator. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test 3. RESTRICTED FUEL SUPPLY LINE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3256 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. 3. Install special 5/16 fuel line adapter tool #6539 between disconnected fuel line and the fuel pump module. 4. Attach a fuel pressure test gauge to the T fitting on tool #6539. 5. Turn the ignition on. 6. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: Non SRT fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). CAUTION: Stop all actuation tests before proceeding. Is the fuel pressure within specification? Yes - Repair or replace fuel supply line as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 4 4. SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes - Go To 5 No - Go To 6 5. FUEL TANK SIPHON HOSE OR FUEL LINE RESTRICTED OR DAMAGED 1. Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Gain access to the fuel pump module and the fuel tank module. 3. Inspect the fuel line and siphon hose between the fuel pump module and the fuel tank module. Look for disconnected or damaged lines and hoses. 4. Inspect the fuel pressure regulator for damage or a condition that might cause a fuel flow problem. Make sure that it is seated in the module properly. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 6 6. FUEL PUMP INLET STRAINER 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3257 WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Remove the fuel pump module and inspect the fuel inlet strainer for damage or a condition that might cause a fuel flow problem. Were any problems found? Yes - Replace the Fuel Pump Inlet Strainer. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. 7. FUEL PUMP GROUND CIRCUIT OPEN OR HIGH RESISTANCE 1. Turn the ignition off. 2. Disconnect the Fuel Pump Module harness connector. 3. Using a 12-volt test light connected to 12 volts, check the Fuel Pump Motor Ground circuit at the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Replace the Fuel Pump Module. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Repair the Fuel Pump Ground circuit for an open circuit or high resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3258 Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down FUEL PRESSURE LEAK DOWN For a complete wiring diagram, refer to the Wiring Information. See: Diagrams/Electrical Diagrams WARNING: Follow these safety precautions to reduce the risk of fire and serious possible serious or fatal injury when performing this test procedure. Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. Use extreme caution when connecting and disconnecting fuel lines. - Considerable fuel leakage may occur when servicing the fuel system. Wear protective eye wear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair / replace as necessary. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978 1. Turn the ignition off. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3259 WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from Gas and Diesel Fuel Pressure/Decay Tester 8978. Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly Fuel Inlet Hose 8978-1 (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect the Reservoir Assembly 534960 (4) to the Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Checking the Fuel Delivery System > Page 3260 - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 2. Turn the ignition on, wait five seconds, turn the ignition off and then wait 1 minute before proceeding. 3. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi). SRT-4 fuel pressure specification is 552 KPa ± 34 KPa (80 psi ± 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the Checking The Fuel Delivery System diagnostic procedure as directed. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Checking the Fuel Delivery System 5. CHECK FUEL DELIVERY SYSTEM FOR LEAK DOWN WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Close the Fuel System Isolation Valve (1) and then wait five minutes before proceeding. 2. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge (1) - Replace the fuel pump module. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Yes - On Fuel Outlet Gauge (2) - Replace the leaking fuel injector(s). - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - If directed here by another test, return to that test. Otherwise, test complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Description Fuel Rail: Description and Operation Description DESCRIPTION The fuel rail supplies the necessary fuel to each individual fuel injector and is mounted to the intake manifold. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Description > Page 3265 Fuel Rail: Description and Operation Operation OPERATION The fuel pressure regulator is no longer mounted to the fuel rail on any engine. It is now located on the fuel tank mounted fuel pump module. Refer to Fuel Pressure Regulator in the Fuel Delivery System for information. The fuel rail is not repairable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal Fuel Rail: Service and Repair Fuel Rail - Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. NOTE: Wrap shop towels around hose to catch any gasoline spillage. 1. Release the fuel system pressure. 2. Disconnect the negative battery cable. 3. Disconnect the fuel line from the fuel rail. Refer to the Quick-Connect Fittings. See: Fuel Line Coupler/Service and Repair 4. Fuel line removed from the fuel rail. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal > Page 3268 5. Unlock and disconnect the electrical connectors from the fuel injectors. 6. Remove the wiring harness from the fuel rail studs. 7. Remove the 2 bolts from the fuel rail. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal > Page 3269 8. Remove the fuel rail and injectors from the intake manifold. 9. Fuel rail removed from intake manifold. 10. Remove fuel injectors from fuel rail. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal > Page 3270 Fuel Rail: Service and Repair Fuel Rail - Installation INSTALLATION 1. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector. 2. Install the fuel injectors to the fuel rail. 3. Install injector into cup of fuel rail. 4. Install retaining clip and check to ensure fuel injector is properly seated. Fuel rail assembly. 5. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal > Page 3271 6. Install the 2 bolts to the fuel rail. Tighten fuel rail bolts to 27 Nm (20 ft. lbs.). 7. Install the wiring harness to the fuel rail. 8. Connect and lock the electrical connectors to the fuel injectors. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal > Page 3272 9. Connect the fuel line to the fuel rail. Refer to Quick Connect Fittings. See: Fuel Line Coupler/Service and Repair 10. Connect the negative battery cable. 11. Use the Scan Tool Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair > Removal Fuel Filler Neck: Service and Repair Removal REMOVAL NOTE: Drain fuel tank if it is more than half full. 1. Remove the negative battery cable. 2. Loosen fuel filler tube cap. 3. Raise vehicle and support. 4. Remove the left rear wheel. 5. Remove the inner splash shield. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair > Removal > Page 3278 6. Disconnect filler tube recirculation vent line. 7. Disconnect fuel filler tube hose from fuel tank neck. 8. Remove filler tube mounting screw. 9. Remove fuel filler tube assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair > Removal > Page 3279 Fuel Filler Neck: Service and Repair Installation INSTALLATION 1. Install fuel filler tube. Connect fuel filler tube hose to fuel tank neck and tighten clamp to 4 Nm (35 in. lbs.). 2. Install fuel filler tube mounting screw and tighten to 9 Nm (79.5 in. lbs.). 3. Connect filler tube vent line. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair > Removal > Page 3280 4. Install the inner splash shield. 5. Install rear tire. 6. Lower vehicle. 7. Install fuel filler tube cap. 8. Install the negative battery cable. 9. Install the air cleaner lid and makeup air hose. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation Fuel Gauge Sender: Customer Interest Instruments - Fuel Gauge Fluctuation NUMBER: 08-024-10 GROUP: Electrical DATE: September 22, 2010 SUBJECT: Fuel Gauge Fluctuation OVERVIEW: This Bulletin involves replacing the fuel sending unit, clocking the fuel module and installing a fuel jumper hose. MODELS: 2007 - 2010 (PM) Caliber (FWD Only) 2007 - 2010 (MK) Compass / Patriot (FWD Only) SYMPTOM/CONDITION: The customer may complain that the fuel gauge is not accurate or fluctuates at 3/4 of a tank or above. DIAGNOSIS: Some customers may experience the condition described above. Preform the repair as described below. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Removal > Front Wheel Drive Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 3289 NOTE: Mark the sending unit at the 4:00 position with 12:00 pointing to the rear of the vehicle. 2. Remove the fuel pump sending unit from the Pump module. 3. Install New Sender to the Fuel Pump Module. 4. Install Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Installation > Front Wheel Drive NOTE: Clock the Fuel Module to the 2:00 position Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 3290 5. Install the jumper hose kit 6. Re-Connect battery 7. Start vehicle and check for leaks 8. Re-install Fuel Pump Cover 9. Re-install padding and rear seat bottom 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation Fuel Gauge Sender: All Technical Service Bulletins Instruments - Fuel Gauge Fluctuation NUMBER: 08-024-10 GROUP: Electrical DATE: September 22, 2010 SUBJECT: Fuel Gauge Fluctuation OVERVIEW: This Bulletin involves replacing the fuel sending unit, clocking the fuel module and installing a fuel jumper hose. MODELS: 2007 - 2010 (PM) Caliber (FWD Only) 2007 - 2010 (MK) Compass / Patriot (FWD Only) SYMPTOM/CONDITION: The customer may complain that the fuel gauge is not accurate or fluctuates at 3/4 of a tank or above. DIAGNOSIS: Some customers may experience the condition described above. Preform the repair as described below. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Removal > Front Wheel Drive Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 3296 NOTE: Mark the sending unit at the 4:00 position with 12:00 pointing to the rear of the vehicle. 2. Remove the fuel pump sending unit from the Pump module. 3. Install New Sender to the Fuel Pump Module. 4. Install Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Installation > Front Wheel Drive NOTE: Clock the Fuel Module to the 2:00 position Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 3297 5. Install the jumper hose kit 6. Re-Connect battery 7. Start vehicle and check for leaks 8. Re-install Fuel Pump Cover 9. Re-install padding and rear seat bottom 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module (AWD) Fuel Gauge Sender: Locations Fuel Pump Module (AWD) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module (AWD) > Page 3300 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module (AWD) > Page 3301 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way Fuel Gauge Sender: Diagrams Fuel Pump Module (FWD) (Body) 4 Way Connector (FWD) - (BODY) 4 WAY MODULE-FUEL PUMP (FWD) - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way > Page 3304 Fuel Gauge Sender: Diagrams Fuel Pump Module C1 (AWD) (Body) 5 Way Connector C1 (AWD) - (BODY) 5 WAY MODULE-FUEL PUMP (AWD) - (BODY) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way > Page 3305 Fuel Gauge Sender: Diagrams Fuel Pump Module C2 (AWD) (Body) 2 Way Connector C2 (AWD) - (BODY) 2 WAY MODULE-FUEL PUMP (AWD) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Gauge Sender: Description and Operation Fuel Pump Module - Description DESCRIPTION - FUEL PUMP MODULE The fuel pump module is located on the top left side of the fuel tank. The fuel pump module contains the following components: - Mounting flange - Electric fuel pump - Fuel pump reservoir - Inlet strainer - Fuel pressure regulator - Fuel level sending unit - Fuel filter The fuel level sending unit (3) is the only serviceable component of the fuel pump module. If the electric fuel pump, fuel pressure regulator or fuel filter requires service, the fuel pump module must be replaced as an assembly. DESCRIPTION The fuel pump module is installed in the top of the fuel tank. The fuel pump module contains the following: - Electric fuel pump - Fuel pump reservoir Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description > Page 3308 - Inlet strainer - Fuel pressure regulator - Fuel gauge sending unit - Fuel supply line connection - Fuel Filter NOTE: The fuel level sending unit is the only serviceable item. If the fuel pump, fuel pressure regulator or fuel filters need service, replace the fuel pump module as an assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description > Page 3309 Fuel Gauge Sender: Description and Operation Fuel Pump Module - Operation OPERATION - FUEL PUMP MODULE An electric fuel pump is located within the fuel pump module. The electric fuel pump is a positive displacement, immersible pump with a permanent magnet electric motor capable of creating 860 kPa (125 psi) of operating pressure. The fuel pressure regulator limits fuel pressure to 400 kPa (58 psi). The fuel gauge is controlled by the instrument cluster circuit board based upon cluster programming and a hard wired input received by the cluster from the fuel level sending unit on the module in the fuel tank. The instrument cluster continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. This information is available to other vehicle control modules via the Controller Area Network (CAN) data bus. Fuel gauge diagnosis is conducted as part ofthe instrument cluster circuitry. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Gauge Sender: Service and Repair Fuel Pump Module - Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. 1. Perform Fuel System Pressure Release procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose. 3. Remove the negative battery cable. 4. Remove the rear seat cushion. 5. Rear seat cushion loose. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3312 6. Remove plastic cover. 7. Clean top of tank to remove loose dirt and debris. 8. Use special tool #9340 to remove left side module lock ring. 9. Note the fuel pump location on the top of the fuel tank. NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3313 10. Pull module up out of fuel tank, make sure that you do not spill fuel inside of vehicle. 11. Drain fuel from fuel pump module. Do not spill fuel in interior of vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3314 Fuel Gauge Sender: Service and Repair Fuel Pump Module - Installation INSTALLATION NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. 1. Wipe seal area of tank clean. Place a new seal between the tank threads and the pump module opening. 2. Install module. 3. Position fuel pump module in tank. Make sure the alignment tab lines up on the fuel tank and pump module for Gas or Diesel fuel tanks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3315 4. While holding the pump module in position, install lock ring and use special tool Spanner Wrench #9340 to tighten lock ring. 5. Install plastic cover. 6. Install rear cushion. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3316 7. Install the negative battery cable. 8. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. 9. Fill fuel tank with clean fuel. Use the Scan Tool to pressurize the system and check for leaks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Main Relay is located in the Fuse/Relay block. Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3320 Main Relay (Computer/Fuel System): Diagrams Connector - (IN F/RB) RELAY-MAIN - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Description and Operation > Oil Pressure Switch - Description Oil Pressure Switch (For Fuel Pump): Description and Operation Oil Pressure Switch - Description DESCRIPTION The oil pressure switch is located on the left front side of the engine block. The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Description and Operation > Oil Pressure Switch - Description > Page 3325 Oil Pressure Switch (For Fuel Pump): Description and Operation Oil Pressure Switch - Operation OPERATION The oil pressure switch is normally "Closed." The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig. The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Raise and support the vehicle See: Maintenance/Vehicle Lifting/Service and Repair 3. Remove the splash shield from the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 4. Remove the accessory drive belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal 5. Remove the three bolts (2) and reposition the A/C compressor (1). 6. Disconnect the oil pressure switch electrical connector. 7. Remove the oil pressure switch using oil pressure socket C-4597 (1) or equivalent. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal > Page 3328 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Installation INSTALLATION NOTE: If the oil pressure switch is removed, it must be replaced with a new switch. CAUTION: The oil pressure switch has tapered threads, over tightening could crack the engine block. 1. Install the oil pressure switch using oil pressure socket C-4597 (1) or equivalent. Tighten switch to 8 Nm (71 in. lbs.). 2. Connect the oil pressure switch electrical connector. 3. Position the A/C compressor (1) and install three mounting bolts (2). Tighten bolts to 25 Nm (18 ft. lbs.). 4. Install the accessory drive belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation 5. Install the splash shield to the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 6. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Main Relay is located in the Fuse/Relay block. Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3333 Main Relay (Computer/Fuel System): Diagrams Connector - (IN F/RB) RELAY-MAIN - (IN F/RB) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3338 Accelerator Pedal Position Sensor: Diagrams Connector - (BODY) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Description and Operation > Oil Pressure Switch - Description Oil Pressure Switch (For Fuel Pump): Description and Operation Oil Pressure Switch - Description DESCRIPTION The oil pressure switch is located on the left front side of the engine block. The oil pressure switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The switch is a two terminal device (one terminal is provided to the wiring harness and the other terminal is the switch's metal housing that screws into the engine block). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Description and Operation > Oil Pressure Switch - Description > Page 3343 Oil Pressure Switch (For Fuel Pump): Description and Operation Oil Pressure Switch - Operation OPERATION The oil pressure switch is normally "Closed." The switch changes from a "Closed" circuit to an "Open" circuit, on increasing pressure of 7 psig. The oil pressure switch changes from an "Open" circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Raise and support the vehicle See: Maintenance/Vehicle Lifting/Service and Repair 3. Remove the splash shield from the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 4. Remove the accessory drive belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal 5. Remove the three bolts (2) and reposition the A/C compressor (1). 6. Disconnect the oil pressure switch electrical connector. 7. Remove the oil pressure switch using oil pressure socket C-4597 (1) or equivalent. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Oil Pressure Switch (For Fuel Pump) > Component Information > Service and Repair > Oil Pressure Switch - Removal > Page 3346 Oil Pressure Switch (For Fuel Pump): Service and Repair Oil Pressure Switch - Installation INSTALLATION NOTE: If the oil pressure switch is removed, it must be replaced with a new switch. CAUTION: The oil pressure switch has tapered threads, over tightening could crack the engine block. 1. Install the oil pressure switch using oil pressure socket C-4597 (1) or equivalent. Tighten switch to 8 Nm (71 in. lbs.). 2. Connect the oil pressure switch electrical connector. 3. Position the A/C compressor (1) and install three mounting bolts (2). Tighten bolts to 25 Nm (18 ft. lbs.). 4. Install the accessory drive belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation 5. Install the splash shield to the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 6. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 3350 Throttle Body: Diagrams Connector (GAS) - (POWERTRAIN) 6 WAY THROTTLE BODY (GAS) - (POWERTRAIN) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Description Throttle Body: Description and Operation Description DESCRIPTION The throttle body mounts to the intake manifold. The throttle position sensor and throttle actuating DC motor are integral to the throttle body. The throttle body is a non serviceable item, replace the throttle body as an assembly. The throttle blade will not close completely when engine is shut down. This engine off blade position is for start up. The electric throttle body will adjust the throttle blade for idle control as the idle air control valve adjusted idle speed previously on cable actuated throttle bodies. The electric throttle body will also adjust the throttle blade for normal driving operation. The throttle blade will move to the engine off blade position if throttle body codes are set to provide air for limp-in mode. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Description and Operation > Description > Page 3353 Throttle Body: Description and Operation Operation OPERATION Filtered air from the air cleaner enters the intake manifold through the throttle body. A throttle valve (plate) is used to supply air for all conditions from idle to wide open throttle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body - Removal Throttle Body: Service and Repair Throttle Body - Removal REMOVAL WARNING: DO NOT place fingers in or around the throttle body plate. If the throttle body is energized, the throttle plate could move causing personal injury. Always disconnect the negative battery cable prior to servicing the throttle body. CAUTION: DO NOT move the throttle plate while power is connected to the throttle body. This may cause fault codes to set. 1. Disconnect and isolate negative battery cable at battery. 2. Remove throttle body air intake hose. 3. Disconnect throttle body electrical connector (1) from throttle body (2). 4. Remove throttle body support bracket bolt (2), if equipped. 5. Remove four bolts (1), throttle body bracket (3) if equipped, and throttle body (4) from intake manifold. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body - Removal > Page 3356 NOTE: Inspect intake manifold to throttle body gasket (2) for damage. Inspect the j-nuts for damage or excessive wear. Replace as necessary. 6. Inspect the four j-nuts (1) for damage or excessive wear, remove if necessary. 7. Inspect intake manifold to throttle body gasket (2) for damage, remove if necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body - Removal > Page 3357 Throttle Body: Service and Repair Throttle Body - Installation INSTALLATION 1. Install a new intake manifold to throttle body gasket (2), if replacement was necessary. 2. Install four new four j-nuts (1), if replacement was necessary. CAUTION: DO NOT OVER TORQUE. Over tightening can cause damage to the throttle body, gaskets, bolts and/or the intake manifold. 3. Install throttle body (4) to intake manifold. 4. Install throttle body support bracket (3), bolt (2) and tighten bracket bolt to 25 Nm (18 ft. lbs.). 5. Install four bolts (1) and hand tighten. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body - Removal > Page 3358 CAUTION: The throttle body must be torqued in a mandatory torque sequence. Tighten in a criss cross pattern to specification. 6. Tighten the bolts in a mandatory torque criss - cross pattern sequence to 7.5 Nm (65 in. lbs.). 7. Connect electrical connector (1) to throttle body (2). 8. Install clean air hose and tighten clamps to 4 Nm (35 in. lbs.). 9. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). 10. Use a scan tool and clear all fault codes then perform the ETC RELEARN function. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Locations > Page 3363 Variable Induction Control Valve: Diagrams Connector (GAS) - (POWERTRAIN) 6 WAY VALVE-MANIFOLD FLOW (GAS) - (POWERTRAIN) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Locations > Page 3364 Variable Induction Control Valve: Description and Operation OPERATION The World Engine is equipped with an intake manifold flow control valve to promote maximum air/fuel atomization. The valve restricts airflow, causing it to tumble or swirl. The tumbling action helps ensure that the fuel and air mix thoroughly and burn faster. The intake manifold flow control valve and variable valve timing work together to improve fuel economy, idle stability, and emissions. The electrically controlled intake manifold flow control valve is located in the intake manifold at the cylinder head. The intake manifold is constructed of composite material and divided into equal length runners. At the end of each runner is an intake manifold flow control valve flap. The intake manifold flow control valve actuator controls the flaps through a common shaft. The intake manifold flow control valve actuator is a two-position torque motor that is pulse-width driven by the GPEC1. The actuator is either energized to move the flaps out of the way to the wide-open position or de-energized to move the flaps up, to a restricted position. The intake manifold flow control valve actuator also contains a potentiometer feedback system to aid in diagnosis. The potentiometer circuit reports the actual position of the intake manifold flow control valve flaps. The GPEC1 compares the actual position with the desired position to ensure that the system is functioning correctly. The intake manifold flow control valve flaps are the mechanical components that restrict airflow to the intake ports. When the valves are moved upward, airflow is restricted and tumble occurs. When the valves are flat against the manifold, the full, unrestricted air charge flows to the intake ports. It is energized under specific operating conditions: At high engine speeds (greater than 3600 rpm on the 1.8 and 2.0 liter or greater than 4000 rpm on the 2.4 liter) or at wide-open throttle, the intake manifold flow control valve actuator is energized and the flaps move to the wide-open position, at lower engine speeds (less than 3600 rpm on the 1.8 and 2.0 liter or less than 4000 rpm on the 2.4 liter), the actuator is de-energized allowing the flaps to remain in the restricted position. The flap is held at that position by the return spring. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Service and Repair > Removal Variable Induction Control Valve: Service and Repair Removal REMOVAL 1. Disconnect negative battery cable. 2. Remove air tube. 3. Disconnect electrical connector (2). 4. Remove mounting bolts (1). 5. Remove valve. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Service and Repair > Removal > Page 3367 Variable Induction Control Valve: Service and Repair Installation INSTALLATION 1. Make sure that slot in shaft is not damaged. 2. Make sure that tab in valve is not damaged. 3. Align tab in valve with slot in intake manifold shaft (2) and rotate valve counterclock wise until valve drops onto location pin mounting (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Valve > Component Information > Service and Repair > Removal > Page 3368 4. Install mounting bolts (1) and tighten to 6 Nm (53 in. lbs.). 5. Connect electrical connector (2). 6. Install air tube. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications FIRING ORDER 1.8, 2.0, 2.4L The firing order is 1-3-4-2. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1/1 (Powertrain) 3 Way Camshaft Position Sensor: Diagrams Camshaft Position Sensor 1/1 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CAMSHAFT 1/1 POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1/1 (Powertrain) 3 Way > Page 3378 Camshaft Position Sensor: Diagrams Camshaft Position Sensor 1/2 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CAMSHAFT 1/2 POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Description DESCRIPTION The camshaft position sensors are mounted to the front and rear of the cylinder head. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description > Page 3381 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Operation OPERATION NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt output reference circuit. A ground for the sensor is provided through the sensor return circuit. The PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the camshaft position sensor. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal Front FRONT 1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor electrical connector. 2. Disconnect negative battery cable. 3. Disconnect electrical connector from camshaft position sensor. 4. Remove camshaft position sensor mounting screws. 5. Remove sensor. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 3384 1. Disconnect negative battery cable. 2. Disconnect electrical connector at sensor. 3. Remove nut retaining heat shield. 4. Pull heat shield out to uncover sensor. 5. Remove mounting bolt. 6. Remove sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 3385 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation Front FRONT 1. Lubricate sensor o-ring. 2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9 Nm (79.5 in. lbs.). 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install the negative battery cable. 5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical connector. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 3386 1. Lubricate sensor o-ring. 2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. 3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Carefully attach electrical connector to camshaft position sensor. Feel for positive lock (click). Installation at angle may damage the sensor pins. 5. Install heat shield onto mounting stud. 6. Install heat shield retaining nut and tighten. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Locations > Page 3390 Condenser: Diagrams Connector (GAS) - (POWERTRAIN) 1 WAY CAPACITOR-IGNITION (GAS) - (POWERTRAIN) 1 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Service and Repair > Ignition Capacitor - Removal Condenser: Service and Repair Ignition Capacitor - Removal REMOVAL 1. Disconnect and isolate negative battery cable at battery. 2. Remove electrical connector (1). 3. Remove mounting bolt (3) and ignition capacitor (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Service and Repair > Ignition Capacitor - Removal > Page 3393 Condenser: Service and Repair Ignition Capacitor - Installation INSTALLATION 1. Install ignition coil capacitor (2) and bolt (3), tighten bolt to 10 Nm (88.5 ft. lbs.). 2. Connect electrical connector (1). 3. Connect the negative battery cable, tighten the nut to 5 Nm (45 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CRANKSHAFT POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The crankshaft position sensor mounts to the rear of the engine block near the transmission. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 3399 Crankshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor (2). The PCM determines which cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth and notches (1), including one long reference tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal REMOVAL The Crankshaft Position Sensor is in the rear of the engine block near the transmission. 1. Remove the engine cover (1). 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner body (1) See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 3402 4. Disengage the upstream O2 sensor wire harness retainer (1) and crankshaft position sensor wire harness retainer (2) from the heat shield (3). 5. Remove one nut (1) and two heat shield retaining bolts (2). 6. Remove heat shield (3). 7. Remove the crankshaft position sensor mounting bolt. 8. Remove sensor with the wire harness attached. 9. Unlock and disconnect the electrical connector from the crankshaft position sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 3403 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation INSTALLATION 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Using a twisting motion, install the crankshaft position sensor. 3. Install the crankshaft position sensor bolt. Tighten the bolt to 9 Nm (80 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 3404 5. Install the heat shield (3) with one nut (1) and two heat shield retaining bolts (2). 6. Install the upstream O2 sensor wire harness retainer (1) and crankshaft position sensor wire harness retainer (2) to the heat shield (3). 7. Install the air cleaner body (1) See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation 8. Connect the negative battery cable. 9. Install the engine cover (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Ignition Coil: Specifications IGNITION RESISTANCE IGNITION COIL RESISTANCE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 (Powertrain) 3 Way Ignition Coil: Diagrams Ignition Coil 1 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY COIL-IGNITION 1 (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 (Powertrain) 3 Way > Page 3410 Ignition Coil: Diagrams Ignition Coil 2 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY COIL-IGNITION 2 (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 (Powertrain) 3 Way > Page 3411 Ignition Coil: Diagrams Ignition Coil 3 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY COIL-IGNITION 3 (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 (Powertrain) 3 Way > Page 3412 Ignition Coil: Diagrams Ignition Coil 4 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY COIL-IGNITION 4 (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3413 Ignition Coil: Testing and Inspection CHECKING THE IGNITION COIL OPERATION For a complete wiring diagram refer to the Wiring Information. See: Diagrams/Electrical Diagrams 1. IGNITION COIL WIRING OR CONNECTORS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3414 NOTE: Diagnose and repair any ignition coil, CMP sensor, or CKP sensor DTCs before proceeding with this test. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Ignition Coil for the cylinder being tested and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. NOTE: If the vehicle is not equipped with the coil on plug ignition system, check the resistance of the ignition wire(s) before checking the cylinder with a spark tester. The resistance should be below 10k ohms. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 2 2. IGNITION COIL OPERATION NOTE: Inspect the ignition coil for damage, carbon tracking on the coil or a damaged spark plug insulator boot. If a problem is found, replace the ignition coil. 1. Turn the ignition off. 2. If the vehicle is equipped with coil on plug ignition system, remove the ignition coil for the cylinder being tested. 3. Disconnect the fuel injector harness connector for the cylinder being tested. 4. For coil on plug ignition systems, install a spark tester(s) on the ignition coil, otherwise install the spark tester to the ignition wire. 5. While cranking the engine observe the spark coming from the spark tester. NOTE: A crisp blue spark that jumps the gap of the spark tester should be generated. Is good spark present? Yes - Go To 7 No - Go To 3 3. MAIN/ASD RELAY OUTPUT CIRCUIT OPEN OR HIGH RESISTANCE 1. Turn the ignition off. 2. Disconnect the Ignition Coil harness connector. 3. Turn the ignition on. 4. With the scan tool, actuate the Main/ASD Relay to on. 5. Using a 12 volt test light connected to ground, check the Main/ASD Relay output circuit in the ignition coil harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright during the actuation? Yes - Go To 4 No - Repair the Main/ASD Relay output circuit for an open circuit or high resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3415 Procedures/Verification Tests/PCM Verification Test. 4. IGNITION COIL WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 1. Using a 12 volt test light connected to 12 volts, check the Ignition Coil control circuit for the cylinder being tested in the Ignition Coil harness connector. 2. Crank the engine for 5 seconds. NOTE: The test light should blink each time the circuit is activated by the PCM. Does the test light blink each time the circuit is activated by the PCM? Yes - Replace the Ignition Coil. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Go To 5 5. IGNITION COIL CONTROL CIRCUIT OPEN OR HIGH RESISTANCE CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals, resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 1. Measure the resistance of the Ignition Coil control circuit for the cylinder being tested between the Ignition Coil harness connector and the appropriate terminal of special tool #8815. Is the resistance below 5.0 ohms? Yes - Go To 6 No - Repair the Ignition Coil control circuit for an open circuit or high resistance. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. 6. POWERTRAIN CONTROL MODULE (PCM) 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Ignition Coil for the cylinder being tested and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Replace and program the Powertrain Control Module (PCM). - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 3416 7. SPARK PLUG(S) 1. Turn the ignition off. 2. Remove the spark plug. 3. Inspect the spark plug for any of the following conditions: Cracks or damage - Carbon tracking - Foreign material - Gap not within specification - Loose or broken electrode NOTE: Lightly tap the bottom of the spark plug on a solid surface. The electrode in the spark plug should not move. Were any problems found? Yes - Replace the spark plug. - Perform the PCM Verification Test. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM Verification Test. No - Test Complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil - Removal Ignition Coil: Service and Repair Ignition Coil - Removal REMOVAL The electronic ignition coil attaches directly to the valve cover. 1. Remove the negative battery cable. 2. Disconnect electrical connector from ignition coil. 3. Remove ignition coil mounting bolts. 4. Remove ignition coil. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil - Removal > Page 3419 Ignition Coil: Service and Repair Ignition Coil - Installation INSTALLATION 1. Install ignition coil. 2. Tighten bolt to 9 Nm (79.5 in. lbs.). 3. Connect electrical connectors and lock. 4. Install the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3423 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3424 Knock Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-KNOCK (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal REMOVAL The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Disconnect the negative battery cable. 2. Remove the bolt holding the knock sensor. 3. Remove sensor with electrical connector attached. 4. Disconnect electrical connector from knock sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 3427 5. Remove the knock sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 3428 Knock Sensor: Service and Repair Knock Sensor - Installation INSTALLATION The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Attach electrical connector to knock sensor. 2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening effects knock sensor performance, possibly causing improper spark control. 3. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1/1 (Powertrain) 3 Way Camshaft Position Sensor: Diagrams Camshaft Position Sensor 1/1 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CAMSHAFT 1/1 POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor 1/1 (Powertrain) 3 Way > Page 3435 Camshaft Position Sensor: Diagrams Camshaft Position Sensor 1/2 (Powertrain) 3 Way Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CAMSHAFT 1/2 POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Description DESCRIPTION The camshaft position sensors are mounted to the front and rear of the cylinder head. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description > Page 3438 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Operation OPERATION NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt output reference circuit. A ground for the sensor is provided through the sensor return circuit. The PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the camshaft position sensor. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal Front FRONT 1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor electrical connector. 2. Disconnect negative battery cable. 3. Disconnect electrical connector from camshaft position sensor. 4. Remove camshaft position sensor mounting screws. 5. Remove sensor. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 3441 1. Disconnect negative battery cable. 2. Disconnect electrical connector at sensor. 3. Remove nut retaining heat shield. 4. Pull heat shield out to uncover sensor. 5. Remove mounting bolt. 6. Remove sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 3442 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation Front FRONT 1. Lubricate sensor o-ring. 2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9 Nm (79.5 in. lbs.). 3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. 4. Install the negative battery cable. 5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical connector. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 3443 1. Lubricate sensor o-ring. 2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into the bore with screw. This can cause sensor to be incorrectly seated causing engine to fail. 3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.). 4. Carefully attach electrical connector to camshaft position sensor. Feel for positive lock (click). Installation at angle may damage the sensor pins. 5. Install heat shield onto mounting stud. 6. Install heat shield retaining nut and tighten. 7. Connect negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 3 WAY SENSOR-CRANKSHAFT POSITION (GAS) - (POWERTRAIN) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description DESCRIPTION The crankshaft position sensor mounts to the rear of the engine block near the transmission. The PCM uses the Crankshaft Position sensor to calculate the following: - Engine RPM - TDC number 1 and 4 - Ignition coil synchronization - Injector synchronization - Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble code). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 3449 Crankshaft Position Sensor: Description and Operation Operation OPERATION The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided through the sensor return circuit. The input to the PCM occurs on a 5 volt output reference circuit that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts) through a transistor in the sensor. When the magnetic field passes over the notches in the crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from 5 to 0 volts, as signaled from the Crankshaft Position sensor (2). The PCM determines which cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth and notches (1), including one long reference tooth and notch. From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle (position). NOTE: The graphic represents the relationship between camshaft and crankshaft sensors edges with camshafts in "lock pin" position (cam shafts are not "phasing"). This is normally seen during idle. Depiction of good camshaft and crankshaft square wave signals for 4 cylinder engines. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal REMOVAL The Crankshaft Position Sensor is in the rear of the engine block near the transmission. 1. Remove the engine cover (1). 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner body (1) See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 3452 4. Disengage the upstream O2 sensor wire harness retainer (1) and crankshaft position sensor wire harness retainer (2) from the heat shield (3). 5. Remove one nut (1) and two heat shield retaining bolts (2). 6. Remove heat shield (3). 7. Remove the crankshaft position sensor mounting bolt. 8. Remove sensor with the wire harness attached. 9. Unlock and disconnect the electrical connector from the crankshaft position sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 3453 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation INSTALLATION 1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor. 2. Using a twisting motion, install the crankshaft position sensor. 3. Install the crankshaft position sensor bolt. Tighten the bolt to 9 Nm (80 in. lbs.). 4. Connect and lock the electrical connector to the crankshaft position sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 3454 5. Install the heat shield (3) with one nut (1) and two heat shield retaining bolts (2). 6. Install the upstream O2 sensor wire harness retainer (1) and crankshaft position sensor wire harness retainer (2) to the heat shield (3). 7. Install the air cleaner body (1) See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation 8. Connect the negative battery cable. 9. Install the engine cover (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Removal Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Removal REMOVAL WARNING: Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. This will disable the front airbag system. Failure to disconnect the battery could result in accidental front airbag module deployment and possible personal injury.Do not place a non-deployed airbag face down on a hard surface as the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. 1. Remove air cleaner fresh air duct (2) and disconnect and isolate negative battery cable at battery, See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal. 2. Remove upper (1) and lower (2) steering column shrouds,See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Removal > Page 3460 3. Remove steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 4. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket integral to the right side of the clockspring (3) on the steering column. 5. Slide the switch away from the clockspring far enough to disengage the slide tab on the bottom of the switch housing from the channel formation in the mounting bracket. Position the multi-function switch (1) aside. 6. Position steering column to the full down position. 7. Position ignition key to the RUN position. 8. Remove screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 9. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and position the SKREEM/WCM (2) back on the lock cylinder housing (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Removal > Page 3461 10. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing. Depress the key cylinder retaining tab. 11. Pull key cylinder (3) and key (2) straight out of the lock cylinder housing as one unit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Removal > Page 3462 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Installation INSTALLATION 1. Place actuator in the lock cylinder housing to the RUN position (if not already there). 2. Insert key into key cylinder and turn key cylinder to the RUN position. 3. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 4. Slide key cylinder into the lock cylinder housing until key cylinder retaining tab locks the cylinder into place. 5. Rotate key back and forth (OFF to START), then remove and reinstall it, making sure key cylinder and lock cylinder housing operate properly. 6. Slide the ring of SKREEM/WCM (2) over lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 7. Install screw (1) fastening the SKREEM/WCM (2) to lock cylinder housing (3). Tighten screw to 2.5 Nm (22 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Removal > Page 3463 8. Install and tighten the screw (2) that secures the mounting tab on the back of the right multi-function switch (1) to the mounting bracket on the clockspring (3). 9. Install steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 10. Install upper (1) and lower (2) steering column shrouds,See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Removal > Page 3464 11. Install air cleaner fresh air duct (2) and disconnect and isolate negative battery cable at battery, See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Installation. 12. Check operation of all steering column mounted components. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3468 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3469 Knock Sensor: Diagrams Connector (GAS) - (POWERTRAIN) 2 WAY SENSOR-KNOCK (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal REMOVAL The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Disconnect the negative battery cable. 2. Remove the bolt holding the knock sensor. 3. Remove sensor with electrical connector attached. 4. Disconnect electrical connector from knock sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 3472 5. Remove the knock sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 3473 Knock Sensor: Service and Repair Knock Sensor - Installation INSTALLATION The knock sensor bolts into the side of the cylinder block in front of the starter under the intake manifold. 1. Attach electrical connector to knock sensor. 2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening effects knock sensor performance, possibly causing improper spark control. 3. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Specifications Spark Plug: Specifications Spark Plug Specifications SPARK PLUGS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Specifications > Page 3478 Spark Plug: Specifications Torque SPARK PLUG Spark Plugs.......................................................................................................................................... ........................................................27 Nm (20 ft. lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3479 Spark Plug: Application and ID Spark Plug Type................................................................................................................................... ....................................................................ZFR5F-11 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal Spark Plug: Service and Repair Spark Plug - Removal REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the electrical connectors from ignition coils. 3. Remove the ignition coil mounting bolt. 4. Twist the ignition coil then pull straight up. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 3482 5. Remove the spark plug using a quality socket with a rubber or foam insert. 6. Inspect the spark plug condition. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 3483 Spark Plug: Service and Repair Spark Plug - Installation INSTALLATION CAUTION: Handle the spark plugs with care. Do not drop or force the spark plugs into the wells, damage to the electrodes and/or porcelain body may occur. Always start each spark plug by hand in order to avoid cross-threading the spark plug in the cylinder head. Always tighten spark plugs to the specified torque. Too much or not enough torque will cause damage to the cylinder head and/or spark plug and may lead to poor engine performance. 1. Install each spark plug to the cylinder head. Tighten spark plugs to 27 Nm (20 ft. lbs.). 2. Install ignition coil onto spark plug. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 3484 3. Install ignition coil mounting bolt. Tighten to 9 Nm (79.5 in. lbs.). 4. Connect ignition coil electrical connectors. 5. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - CVT > Pressure Regulating Solenoid, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - CVT > Pressure Regulating Solenoid, CVT > Component Information > Locations > Page 3491 Pressure Regulating Solenoid: Diagrams Connector - (BODY) 22 WAY ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH - (BODY) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - CVT > Shift Solenoid, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - CVT > Shift Solenoid, CVT > Component Information > Locations > Page 3495 Shift Solenoid: Diagrams Connector - (BODY) 22 WAY ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH - (BODY) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Transmission Control Module C1 (CVT) (Body) 24 Way Control Module: Diagrams Transmission Control Module C1 (CVT) (Body) 24 Way Connector C1 (CVT) - (BODY) 24 WAY MODULE-TRANSMISSION CONTROL (CVT) - (BODY) 24 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Transmission Control Module C1 (CVT) (Body) 24 Way > Page 3502 Control Module: Diagrams Transmission Control Module C2 (CVT) (Body) 24 Way Connector C2 (CVT) - (BODY) 24 WAY MODULE-TRANSMISSION CONTROL (CVT) - (BODY) 24 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation Control Module: Description and Operation Operation OPERATION Shift Control In order to select the gear ratio which can obtain the driving force in accordance with driver's intention and the vehicle condition, TCM monitors the driving conditions, such as the vehicle speed and the throttle position and selects the optimum gear ratio, and determines the gear change steps to the gear ratio. Then it sends the command to the stepping motor, and controls the flow-in/flow-out of line pressure to/from the primary pulley to determine the position of the moving-pulley and control the gear ratio. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 3505 Selection of the gear ratio is set for every position separately. "Drive" Position Shifting is available over all the ranges of gear ratios from the lowest to the highest. When using the Manual Mode (Vehicles with the manual mode) When the manual mode switch is turned ON, the fixed changing gear line is set. By moving the switch to + side or - side, shift change is like a M/T and selects from a range of 6 pre-programmed gear ranges. By limiting the shift to the area nearest the low side of the gear ratio, a larger driving force and engine brake are secured. Downhill Engine Brake Control When a downhill condition is detected while the accelerator pedal is released, the engine brake will be increased by downshifting so as to limit acceleration of the vehicle. Also, if uphill is detected, acceleration performance is improved by limiting the shift area on the highest side of the gear ratio. Acceleration Control According to vehicle speed and a increase of accelerator pedal angle, driver's request for acceleration as well as driving conditions are measured. At the time of starting or acceleration while moving, this function improves in acceleration feeling by making the engine speed proportionate to the vehicle speed. Even at the time of slower acceleration, a shift map which can gain a larger driving force is chosen for compatibility of mileage with drivability. Line Pressure and Secondary Pressure Control Control of line pressure and secondary pressure with a high degree of accuracy has reduced friction and improved fuel economy. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 3506 Normal Fluid Pressure Control The line pressure and the secondary pressure are optimized depending on driving conditions, on the basis of the throttle position, the engine speed, the primary pulley (input) revolution speed, the secondary pulley (output) revolution speed, the stop lamp SW signal, the PNP switch signal, the lock-up signal, the voltage, the target gear ratio, the fluid temperature, and the fluid pressure. Secondary Pressure Feedback Control When controlling the normal fluid pressure or the fluid pressure at the time of selection, the secondary pressure can be set more accurately by using the fluid pressure sensor to detect the secondary pressure and performing the feedback control. Lock-up Control The lock-up applied gear range has been expanded by locking up the torque converter at a lower vehicle speed than conventional A/T models. Selection Control When selecting between N (P) and D(R) position, the optimum operating pressure is set on the basis of the throttle position, the engine speed, and the secondary pulley (output) revolution speed to lessen the select shock. CAN Communication Real-time communications (signal exchanges) are maintained among the control units such as the CVT, C/U, ECM, combination meter etc. Each unit is controlled optimally depending on vehicle driving conditions while sharing information and in cooperating with the other control units. In CAN (Controller Area Network) communication, control units are connected with two communication lines (CAN-H line, CAN-L line) allowing a high rate of information to be transmitted by fewer wirings. Each control unit transmits/receives data but selectively reads required data only. Inputs and Outputs Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 3507 Engine/CVT Integration Control (CAN Communication Control) In order to improve gearshift feeling and to perform controls such as prevention of engine slowdown, engine power control signals are intercommunicated between the engine ECM and the TCM, and real-time cooperative controls depending on vehicle driving conditions are performed. TCM sends information such as fast slowdown signals, lock-up signals, torque down request signals to ECM, while receiving information such as torque down permission/prohibition signals, lock-up permission/prohibition signals, throttle position from ECM. Fail-safe Function If an unexpected signal is sent from any sensor, switch, solenoid etc., this function controls the CVT to make driving as smooth as possible. Secondary Speed Sensor The shift pattern is changed in accordance with throttle position when an unexpected signal is sent from the output speed sensor (secondary speed sensor) to the TCM. The manual mode position or the sports mode position is inhibited, and the transaxle is put in "D". Primary Speed Sensor The shift pattern is changed in accordance with throttle position and secondary speed (vehicle speed) when an unexpected signal is sent from the primary speed sensor to the TCM. The manual mode function or the sports mode function is inhibited, and the transaxle is put in "D". PNP Switch If an unexpected signal is sent from the PNP switch to the TCM, the transaxle is put in "D". Fluid Temperature Sensor If an unexpected signal is sent from the fluid temperature sensor to the TCM, the gear ratio obtained immediately before receiving the unexpected signal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 3508 is maintained and the gear ratio is controlled to keep engine speed under 5,000 rpm (approximately), depending on driving conditions. Secondary Pressure Sensor If an unexpected signal is sent from the secondary pressure sensor to the TCM, the secondary pressure feedback control is stopped and the offset value obtained immediately before the non-standard condition occurs is used to control line pressure. Line Pressure Solenoid If an unexpected condition of the solenoid is detected by the TCM, the line pressure solenoid is turned OFF to achieve the maximum fluid pressure. Secondary Pressure Solenoid If an unexpected condition of the secondary solenoid is detected by the TCM, the secondary pressure solenoid is turned OFF to achieve the maximum fluid pressure. Lock-up solenoid If an unexpected condition of the lock-up solenoid is detected by the TCM, the lock-up solenoid is turned OFF to cancel the lock-up. Stepping Motor If an unexpected condition of the stepping motor is detected by the TCM, the stepping motor coil phases "A" through "D" are all turned OFF to hold the gear ratio used immediately before the unexpected condition occurred. Lock-up/Selection Switching Solenoid If an unexpected condition of the solenoid is detected by the TCM, the lock-up/selection switching solenoid is turned OFF to cancel the lock-up. Backup Power Supply Transaxle assembly is protected by limiting the engine torque when the memory back-up power supply for controlling from the battery is not supplied to the TCM. Normal status is restored when turning the ignition switch OFF to ON after power is normally supplied TCM - 1. Shift control - 2. Line pressure control - 3. Selection control - 4. Lock-up control - 5. Engine/CVT integration control [CAN communication control] - 6. Self-diagnosis function - 7. Fail-safe function Primary Speed Sensor, Secondary Speed Sensor Primary Speed Sensor It is installed near the CVT fluid cooler in the transaxle case. It sends rotating speed of the primary pulley (input shaft) to the TCM as a pulse signal. Secondary Speed Sensor It is installed near the output gear part in the transaxle case. It sends rotating speed of the secondary pulley (output shaft) to the TCM as a pulse signal. TCM converts the pulse signal to vehicle speed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures Control Module: Procedures Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. TCM Initialization TRANSMISSION CONTROL MODULE INITIALIZATION NOTE: Refer to the following table when the Transmission Control Module (TCM) and/or transaxle has been replaced to determine if the TCM memory must be erased. INITIAL LEARN (BRAND-NEW MODULE, MEMORY ALREADY CLEAR) Battery must be connected. If the Totally Integrated Power Module (TIPM) is to be configured, configure the TIPM and then turn ignition key to OFF/LOCKED briefly, then back to RUN. The shifter must be in PARK or NEUTRAL, engine not running. 1. Turn the ignition key to RUN for 4 seconds to allow reading of new values. 2. Turn ignition key to OFF/LOCKED for 2 seconds to allow storing new values in EEROM. 3. Turn the ignition key to RUN, with scan tool clear DTCs. 4. Turn ignition key to OFF/LOCKED for 2 seconds. 5. After at least 7 seconds, read DTCs. 6. If DTCs resets See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Testing and Inspection RELEARN, AFTER REPLACING A TRANSAXLE 1. Turn ignition key to RUN. 2. Clear learning memory using the scan tool. 3. Turn the ignition key to OFF/LOCKED for 2 seconds. 4. Turn the ignition key to RUN Clear DTCs. 5. Turn the ignition key to OFF/LOCKED for 2 seconds. 6. Turn ignition key to RUN. 7. After at least 7 seconds, read DTCs. 8. If DTCs resets See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Testing and Inspection Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 3511 Control Module: Removal and Replacement Removal REMOVAL 1. The TCM (2) is located between the brake pedal bracket (1) and the left kick panel (3). 2. Unplug the two electrical connectors (2) at the TCM. 3. Remove the two nuts (1) that hold the TCM to the bulkhead. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 3512 4. Remove the TCM. Installation INSTALLATION 1. Install TCM mounting bracket holes (1) over the two studs on the bulkhead. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 3513 2. Install the two nuts to mounting studs (1) on the bulkhead and tighten to 15 Nm (130 in. lbs.). 3. Plug in electrical connectors (2) to TCM (3). NOTE: If a new TCM is installed a learn procedure must be performed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 3518 Control Module: Diagrams Connector (AWD) - (BODY) 16 WAY MODULE-ALL WHEEL DRIVE CONTROL (AWD) - (BODY) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations > Page 3524 Fluid Pressure Sensor/Switch: Diagrams Connector - (BODY) 22 WAY ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH - (BODY) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Speed Sensor, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation DESCRIPTION The Vehicle Speed Sensor (VSS) is a hall effect sensor mounted above the transaxle differential. The sensor is triggered by the ring gear teeth passing below it. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Vehicle Speed Sensor - Removal Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor - Removal REMOVAL 1. Open hood. 2. Remove the air cleaner housing.See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal 3. Disconnect the speed sensor connector. CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 4. Remove speed sensor retaining bolt. 5. Remove speed sensor from transaxle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Vehicle Speed Sensor - Removal > Page 3537 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor - Installation INSTALLATION 1. Using a NEW O-ring, install the speed sensor to the transaxle. 2. Install the bolt and tighten to 7 Nm (60 in. lbs.). 3. Connect speed sensor connector. 4. Install the air cleaner housing.See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3546 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3547 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3548 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3549 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3550 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3551 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3552 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3553 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3554 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3555 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3556 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's P0139/P0571 Set NUMBER: 18-018-09 GROUP: Vehicle Performance DATE: June 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For Diagnostic Trouble Code P0139 Or P0571 Is Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey 2009 (JS) Sebring/Avenger/Sebring Convertible 2009 (PM) Caliber 2009 (MK) Compass/Patriot NOTE: This bulletin applies to: - 2009 JS vehicles equipped with a 2.0L/2.4L Engine (Sales Code ECN or EDG or ED3) built before July 27, 2009 (MDH 0727XX) - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before July 27, 2009 (MDH 0727XX) - 2009 PM/MK vehicles equipped with a 1.8L, 2.0L or 2.4L engines (Sales Codes EBA, ECN and ED3) built before July 10, 2009 (MDH 0710XX) SYMPTOM/CONDITION: Some customers may experience a MIL illumination. The MIL is for P0139 - 02 Sensor 1/2 Slow Response. Further investigation by the technician may also find DTC P0571. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other then the ones listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set > Page 3562 If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0139/P0571 Set NUMBER: 18-018-09 GROUP: Vehicle Performance DATE: June 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For Diagnostic Trouble Code P0139 Or P0571 Is Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey 2009 (JS) Sebring/Avenger/Sebring Convertible 2009 (PM) Caliber 2009 (MK) Compass/Patriot NOTE: This bulletin applies to: - 2009 JS vehicles equipped with a 2.0L/2.4L Engine (Sales Code ECN or EDG or ED3) built before July 27, 2009 (MDH 0727XX) - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before July 27, 2009 (MDH 0727XX) - 2009 PM/MK vehicles equipped with a 1.8L, 2.0L or 2.4L engines (Sales Codes EBA, ECN and ED3) built before July 10, 2009 (MDH 0710XX) SYMPTOM/CONDITION: Some customers may experience a MIL illumination. The MIL is for P0139 - 02 Sensor 1/2 Slow Response. Further investigation by the technician may also find DTC P0571. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other then the ones listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set > Page 3568 If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3573 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3574 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3575 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3576 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3577 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3578 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3579 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3580 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3581 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3582 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3583 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0139/P0571 Set NUMBER: 18-018-09 GROUP: Vehicle Performance DATE: June 23, 2009 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For Diagnostic Trouble Code P0139 Or P0571 Is Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2009 (JC) Journey 2009 (JS) Sebring/Avenger/Sebring Convertible 2009 (PM) Caliber 2009 (MK) Compass/Patriot NOTE: This bulletin applies to: - 2009 JS vehicles equipped with a 2.0L/2.4L Engine (Sales Code ECN or EDG or ED3) built before July 27, 2009 (MDH 0727XX) - 2009 JC vehicles equipped with a 2.4L engine (sales code ED3 or EDG) built before July 27, 2009 (MDH 0727XX) - 2009 PM/MK vehicles equipped with a 1.8L, 2.0L or 2.4L engines (Sales Codes EBA, ECN and ED3) built before July 10, 2009 (MDH 0710XX) SYMPTOM/CONDITION: Some customers may experience a MIL illumination. The MIL is for P0139 - 02 Sensor 1/2 Slow Response. Further investigation by the technician may also find DTC P0571. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other then the ones listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-09 > Jun > 09 > Engine Controls - MIL ON/DTC's P0139/P0571 Set > Page 3589 If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules - Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM Programming - Gas. After PCM reprogramming, the following must be performed: a. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow the tech to clear them. 2. Type the necessary information on the "Authorized Modification Label" and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update Technical Service Bulletin # H33 Date: 081106 Recall - PCM Replacement/Software Update November 2008 Dealer Service Instructions for: Safety Recall H33 Powertrain Control Module Models 2009 (PM) Dodge Caliber (MK) Jeep(R) Compass and Patriot (JS) Chrysler Sebring and Dodge Avenger (JC) Dodge Journey NOTE: This recall applies only to the above vehicles built from July 10, 2008 through August 26, 2008 (MDH 071011 through 082606). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Powertrain Control Module (PCM) on about 680 of the above vehicles may have been manufactured with an adhesive that could cause the printed circuit board to break. This can cause the engine to stall and result in a crash without warning. Repair The PCM must be replaced and the correct software programmed into the new module. Parts Information Special Tools Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3595 These specials tool are required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3596 Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Caution Information CAUTION: To avoid a possible voltage spike that could damage the PCM, the ignition key must be in the "OFF" position and the negative battery able must be disconnected before unplugging the PCM connectors. A. PCM Replacement For PM/MK Models (See Section "B" For JS/JC Models) 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3597 c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect the negative battery cable. 5. Unlock and disconnect the electrical connectors from the PCM. 6. Remove the air cleaner box. 7. Remove the three PCM mounting bolts (Figure 1). 8. Tip the PCM out and remove it from the mounting bracket. 9. Place the new PCM into the mounting bracket. 10. Install the three mounting bolts and tighten them to 80 in. lbs. (9 N.m) (Figure 1). 11. Connect the PCM electrical connectors and engage the electrical connector locks. 12. Install the air cleaner box. 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. B. PCM Replacement For JS/JC Models 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3598 NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Determine the PCM software part number using the following procedure: Using StarSCAN: a. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. b. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. c. Starting at the "Home" screen select "ECU View". d. Touch the screen to highlight "PCM" in the list of modules. e. Select "More Options". f. Select "ECU Flash". g. Record the part number at the top of the Flash PCM screen for later reference. Using StarMOBILE: a. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. b. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. c. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. d. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. e. From the desktop, launch the "StarMOBILE Desktop Client" software. f. Establish a connection with the StarMOBILE scan tool. g. Starting at the "Home" screen select "ECU View". h. Touch the screen to highlight "PCM" in the list of modules. i. Select "More Options". j. Select "ECU Flash". k. Record the part number at the top of the Flash PCM screen for later reference. 3. Place the Ignition in the "OFF" position. 4. Disconnect and remove the battery charger. 5. Disconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3599 6. Disconnect both PCM electrical connectors (Figure 2). 7. Remove the two PCM mounting bracket retaining nuts and remove the PCM and mounting bracket as an assembly (Figure 2). 8. Remove the four mounting screws that hold the PCM to the mounting bracket. 9. Install the new PCM on to the mounting bracket. 10. Install the four PCM-to-mounting bracket retaining screws. Tighten the screws to 95 lbs. in. (11 N.m) (Figure 2). 11. Install the PCM and bracket into the vehicle. Tighten the two mounting nuts to 95 in. lbs. (11 N.m). 12. Connect both PCM electrical connectors (Figure 2). 13. Connect the negative battery cable. 14. Continue with Section C. Program PCM. C. Program PCM NOTE: Either StarSCAN or StarMOBILE can be used to perform this recall. This procedure must be performed with the latest software release level. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. PCM Programming Procedure using StarSCAN 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Home" screen, follow the procedure below: a. Select "ECU View" b. Touch the screen to highlight "PCM" in the list of modules. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3600 c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in the PCM replacement procedure Step 2g for StarSCAN. i. Select "Download to Scantool". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 6. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen," select "ECU View". b. Select "TCM". c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 7. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the StarSCAN screen. f. Press the "Next" button on the StarSCAN screen. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT > Parts > Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process. 8. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3601 b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 9. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the StarSCAN screen. e. Follow the screen prompts to complete the process. 10. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 11. Place the Ignition in the "OFF" position, then Power "Off" the StarSCAN. 12. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 13. Place the ignition in the "RUN" position and then Power "ON" the StarSCAN. 14. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the StarSCAN. e. Follow the on screen instructions. f. When complete, select "Finish". 15. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3602 c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions.en instructions. 16. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, and battery charger from the vehicle. PCM Module Programming Procedure using StarMOBILE 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge. NOTE: Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarMOBILE ethernet cable to the StarMOBILE and the dealer's network drop. 3. Connect the CH9404 StarMOBILE vehicle cable to the StarMOBILE and the vehicle. 4. Place the Ignition in the "RUN" position, then Power "ON" the StarMOBILE. 5. Record the StarMOBILE I.P. address displayed on the StarMOBILE screen. 6. From the desktop, launch the "StarMOBILE Desktop Client" software. 7 Establish a connection with the StarMOBILE scan tool.BILE scan tool. 8. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Home" screen, follow the procedure below: a. Select "ECU View". b. Touch the screen to highlight "PCM" in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Select "Browse for New File". f. Enter Identification name and password. g. Press "Finish". h. Highlight the appropriate calibration based on the part number recorded in Step 2k. of the PCM replacement procedure for StarMOBILE. i. Select "Download to Client". j. Select "Close" after the download is complete, then select "Back". k. Highlight the listed calibration. l. Select "Update Controller" and follow the on screen instructions. m. When the update is completed, select "OK". n. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. 9. Vehicles equipped with a Continuously Variable Transaxle (CVT), ensure that the Transmission Control Module (TCM) has the latest software calibration available using the following procedure: a. From the "Home Screen" select "ECU View". b. Select "TCM". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3603 c. Select "More Options". d. Select "ECU Flash" e. Select "Browse for File". f. Follow the screen prompts to complete the process. 10. Vehicles equipped with a Wireless Control Module (WCM), perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "WCM Wireless Control". c. Select "Misc. Functions". d. Scroll down the list and select "PCM Replaced". e. Press the blue "Start" button on the Desktop Client. f. Press the "Next" button on the Desktop Client. g. Enter the Personal Identification Number (PIN) for that vehicle NOTE: The PIN number can be obtained from the original selling invoice, DealerCONNECT>Parts>Key Codes, or contacting the District Manager. h. Follow the screen prompts to complete the process 11. Vehicles not equipped with a Wireless Control Module, perform the following procedure: a. Starting at the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM VIN" and follow the on screen instructions. e. When complete, select "Finish". 12. Perform the learn Electronic Throttle Control (ETC) programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Learn ETC" and press the "Start" button on the Desktop Client. e. Follow the screen prompts to complete the process. 13. Check the PCM Odometer programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "PCM". c. Select "Misc. Functions". d. Select "Check PCM Odometer" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3604 f. When complete, select "Finish". 14. Place the Ignition in the "OFF" position, then Power "Off" the StarMOBILE. 15. Disconnect the Data Link Connector (DLC), wait 15 seconds, and reconnect the DLC to the vehicle. 16. Place the ignition in the "RUN" position, power "ON" the StarMOBILE and restart the Desktop Client. 17. Vehicles equipped with a four-speed transaxle, perform Transmission Control Module (TCM) Quicklearn programming using the following procedure: a. From the "Home" screen, select "ECU View". b. Select "TCM Transmission Control Module". c. Select "Misc. Functions". d. Select "Quicklearn" and press the "Start" button on the Desktop Client. e. Follow the on screen instructions. f. When complete, select "Finish". 18. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the "Home" screen select "System View". b. Select "All DTCs". c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list. d. Follow the on screen instructions. 19. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE cable, and battery charger from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > H33 > Nov > 08 > Recall - PCM Replacement/Software Update > Page 3605 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - CVT > Pressure Regulating Solenoid, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - CVT > Pressure Regulating Solenoid, CVT > Component Information > Locations > Page 3612 Pressure Regulating Solenoid: Diagrams Connector - (BODY) 22 WAY ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH - (BODY) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - CVT > Shift Solenoid, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - CVT > Shift Solenoid, CVT > Component Information > Locations > Page 3616 Shift Solenoid: Diagrams Connector - (BODY) 22 WAY ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH - (BODY) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3623 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3628 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation > Modular Clutch Assembly - Description Clutch Disc: Description and Operation Modular Clutch Assembly - Description DESCRIPTION The modular clutch assembly (1) is located between the engine and manual transaxle in the transaxle bellhousing, and is responsible for transmitting engine power to the transaxle. The modular clutch is an assembly which incorporates a the following components: - Flywheel - Clutch Disc - Pressure Plate - Diaphragm Spring - Sensor - Cover Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation > Modular Clutch Assembly - Description > Page 3634 Clutch Disc: Description and Operation Modular Clutch Assembly - Operation OPERATION The modular clutch assembly is designed to transmit power from the engine to the manual transaxle. This is accomplished by the friction and clamping force generated when the spring loaded pressure plate locks the clutch disc to the flywheel. The clutch disc, which is splined to the transaxle input shaft, transmits power until the center of the diaphragm spring is depressed, and the clamp force is removed from the disc. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Procedures Clutch Disc: Procedures INSPECTION Fluid contamination is a frequent cause of clutch malfunctions. Oil, grease, water, or other fluids on the clutch contact surfaces will cause faulty operation. During inspection, note if any components are contaminated. Look for evidence of oil, grease, or water/road splash on clutch components. OIL CONTAMINATION Oil contamination indicates a leak at the rear main seal and/or transaxle input shaft. Oil leaks produce a residue of oil on the transaxle housing interior, clutch cover and flywheel. Heat buildup caused by slippage can bake the oil residue onto the components. This glaze-like residue ranges in color from amber to black. GREASE CONTAMINATION Grease contamination is usually a product of over-lubrication. During clutch service, apply only a small amount of grease to the input shaft splines. Excess grease may be thrown off during operation, contaminating the disc. ROAD SPLASH/WATER CONTAMINATION Road splash contamination is usually caused by driving the vehicle through deep water puddles. Water can be forced into the clutch housing, causing clutch components to become contaminated. Facing of disc will absorb moisture and bond to the flywheel and/or, pressure plate, if vehicle is allowed to stand for some time before use. If this condition occurs, replacement of clutch assembly may be required. Drive the vehicle until normal clutch operating temperature has been obtained. This will dry off disc assembly, pressure plate, and flywheel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Procedures > Page 3637 Clutch Disc: Removal and Replacement Modular Clutch Assembly - Removal REMOVAL WARNING: Chrysler does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on manual clutch parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris 1. Remove transaxle (3) from vehicle See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/T355 Manual Transmission - Removal. 2. Remove modular clutch assembly (1) from transaxle input shaft. Modular Clutch Assembly - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Procedures > Page 3638 INSTALLATION WARNING: Chrysler does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on manual clutch parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris 1. Install clutch module onto input shaft. 2. Install transaxle into vehicleSee: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/T355 Manual Transmission Installation. Clutch Disc - Removal REMOVAL DIESEL WARNING: Chrysler does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on manual clutch parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Procedures > Page 3639 1. Remove transaxle assembly See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/T355 Manual Transmission Removal. 2. Mark position of pressure plate (3) on flywheel (1) with paint or scribe for assembly reference. 3. Loosen and remove six pressure plate-to-flywheel bolts. Remove pressure plate (3) and clutch disc (2). 4. Remove eight flywheel-to-crankshaft bolts and remove flywheel assembly (1). GAS WARNING: Chrysler does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on manual clutch parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris 1. Remove transaxle assembly See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/T355 Manual Transmission Removal. 2. Remove the modular clutch assembly (1). Clutch Disc - Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Procedures > Page 3640 DIESEL WARNING: Chrysler does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on manual clutch parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris 1. Inspect clutch release bearing and lever for excessive wear and replace as necessary. The release bearing is integral to the Concentric Slave Cylinder (CSC). 2. Clean the surfaces of the flywheel (1) and pressure plate to make certain that all oil, grease, and rust have been removed. 3. Verify the crankshaft mounting flange is free of debris, oil, grease, etc. Position the flywheel (1) onto the engine crankshaft. 4. Install flywheel to crankshaft. Install eight (8) flywheel-to-crankshaft bolts and tighten to 45 Nm (33 ft. lbs.) plus an additional 1/4 turn (90 degrees). 5. Apply a very light coating of grease to the splines in the clutch disc hub. 6. Position the clutch disc (2) to the flywheel (1). Make sure the side marked "FLYWHEEL SIDE" faces the flywheel (1). 7. Install the clutch pressure plate (1) to the flywheel and clutch disc. Finger tighten the six pressure plate-to-flywheel bolts. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Procedures > Page 3641 8. Use Clutch Alignment Tool 6724 (3) to position the clutch disc (2) to the center of the flywheel (1). 9. Tighten pressure plate bolts (2) evenly and in rotation a few threads at a time The bolts must be tightened evenly and to specified torque to avoid distorting the pressure plate. 10. Using a "criss-cross" pattern, torque pressure plate bolts (2) to 31 Nm (23 ft. lbs.). Remove the clutch disc alignment tool. 11. Apply light coat of MOPAR(R) High Temperature Bearing Grease or equivalent to clutch disc hub and splines of transmission input shaft. CAUTION: Do not over lubricate shaft splines. This will result in grease contamination of disc. 12. Install transaxle See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/T355 Manual Transmission - Installation. GAS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Procedures > Page 3642 WARNING: Chrysler does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on manual clutch parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris 1. Install new modular clutch assembly onto input shaft of transmission. 2. Install the transmission See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/T355 Manual Transmission Installation . Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3648 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Page 3649 Clutch Fluid: Specifications Mopar DOT 3, SAE J1703 should be used. No other type of fluid is recommended or approved for use in the clutch hydraulic system. Use only Mopar brake fluid or equivalent from a tightly sealed container. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Description and Operation > Description Clutch Master Cylinder: Description and Operation Description DESCRIPTION NOTE: The clutch master cylinder/hydraulic release system does not have its own reservoir. This system is supplied fluid from the brake master cylinder reservoir. The clutch master cylinder (2) mounts to the clutch pedal and consists of a push rod, a piston and cylinder housing, an interconnecting hydraulic tube and a supply hose which connects to the brake master cylinder reservoir (1) for fluid supply. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Description and Operation > Description > Page 3654 Clutch Master Cylinder: Description and Operation Operation OPERATION When the clutch pedal is depressed, the push rod moves the piston in the master cylinder (2), displacing fluid through the hydraulic line and into the release bearing. The release bearing is forced into the fingers of the clutch diaphragm springs. As the fingers move, they release the clamping pressure on the clutch disc between the clutch pressure plate and the flywheel. The clutch becomes disengaged as this pressure is released. When the clutch pedal is released, the system hydraulic pressure is released. This allows the force of the clutch diaphragm springs to return to their original position, re-clamping the clutch disc between the flywheel and the clutch pressure plate. Also, the release bearing and lever are forced to return, which reverses the movement of the hydraulic system and returns the pedal to its original position against the up-stop. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder - Removal Clutch Master Cylinder: Service and Repair Clutch Master Cylinder - Removal REMOVAL CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water. NOTE: Before proceeding, See: Brakes and Traction Control/Service Precautions/Technician Safety Information See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings . 1. Remove engine cover. 2. Disconnect and isolate the battery negative cable from its post on the battery. 3. Remove the air cleaner cover (3) and the air intake hose (2) to the hose (1) leading down the back of the engine. 4. Remove the PCM bracket mounting nut (1) to upper shock tower stud (if equipped). 5. Remove the PCM bracket mounting bolt (2) to lower shock tower (if equipped). 6. Reposition the PCM and bracket (4) out of the way (if equipped). 7. Remove the master cylinder See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Brake Master Cylinder - Removal. 8. Remove the left front brake tube from the clip located on the left body rail. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder - Removal > Page 3657 9. Disconnect the rear brake tubes (1) at the junction block (2). Install plugs at all of the open brake tubes. 10. Pull the tube bundle routing clip (with tubes) loose from the stud on the left side of the dash panel. 11. Remove the bolt (1) for the relay bracket (2) on the fuel filter (3) and reposition the relay out of the way of the brake booster (if equipped). 12. Disconnect the vacuum hose (2) from the check valve (1) on the power brake booster. Do not remove the check valve from power brake booster. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder - Removal > Page 3658 13. Remove the steering column opening cover from the instrument panel. 14. Remove the steering column cover reinforcement mounting screws (2). Remove the steering column cover reinforcement (1) (if equipped). 15. Remove the stop lamp switch See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Removal. 16. Remove the retaining clip (2) securing the power brake booster push rod (1) to the brake pedal. To do so, position a small screwdriver under the center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin (3). Remove and discard the clip. Do not reuse the clip. 17. Slide the booster push rod (1) off the brake pedal pin (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder - Removal > Page 3659 18. Remove the four nuts (4) attaching the power brake booster (3) to the dash panel. 19. Slide the power brake booster (3) forward until its mounting studs clear the dash panel, then remove it through the engine compartment. CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water. 20. Disconnect hydraulic tube (6) at the clutch master cylinder pressure line connector (5) by pulling retaining clip then pulling out on tube. Cap off hydraulic tube to prevent fluid loss. To completely drain clutch master cylinder and tubing, remove brake master cylinder cap and drain fluid into suitable container. 21. Disconnect clutch master cylinder pushrod (3) from clutch pedal. 22. Remove master cylinder assembly (4) from mounting position by turning 1/4 turn clockwise. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder - Removal > Page 3660 Clutch Master Cylinder: Service and Repair Clutch Master Cylinder - Installation INSTALLATION CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water. 1. Install clutch master cylinder body (4) to the clutch pedal bracket assembly and 1/4 turn counter clockwise to secure. 2. Insert hydraulic tube (6) into master cylinder pressure-line connector (5) and install retaining clip. 3. Connect clutch master cylinder rod (3) to clutch pedal pin. An audible "click" should be heard. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder - Removal > Page 3661 NOTE: Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs. 4. Install the power brake booster (3) by sliding the push rod and studs through the dash panel and into mounting position. 5. Under the instrument panel, install the four power brake booster mounting nuts (4). To tighten the nuts, refer to the following step. CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence. 6. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 Nm (17 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder - Removal > Page 3662 7. Using Mopar(R) Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster input rod (1). 8. Install the power brake booster push rod (1) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of the pin. Do not reuse the old clip. 9. Install and adjust the stop lamp switch in the brake pedal bracket See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Installation. 10. Install the steering column cover reinforcement (1) (if equipped) using the four mounting screws (2). 11. Install the steering column opening cover on the instrument panel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder - Removal > Page 3663 CAUTION: When installing the vacuum hose on the check valve (1), make sure the hose is routed properly to avoid possible contact with unfriendly surfaces. 12. Connect the vacuum hose (2) to the vacuum check valve (1). 13. Install the relay bracket (2) to the fuel filter (3) using mounting bolt (1) (if equipped). 14. Install the tube bundle routing clip (with tubes) onto the stud on the left side of the dash panel. 15. Connect the rear brake tubes (1) to the junction block (2). Tighten the tube nuts to 17 Nm (150 in. lbs.). 16. Install the left front brake tube into the clip located on the left body rail. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Clutch Master Cylinder - Removal > Page 3664 17. Install the master cylinder See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Brake Master Cylinder - Installation. 18. Verify that brake master cylinder reservoir (1) is full. Top off with DOT 3 brake fluid if necessary. 19. Reposition the PCM and bracket (4) into mounting position (if equipped). 20. Install bolt (2) for the PCM mounting bracket to lower shock tower and tighten to 9 Nm (80 in. lbs.) (if equipped). 21. Install nut (1) for the PCM mounting bracket to upper shock tower stud and tighten to 9 Nm (80 in. lbs.) (if equipped). 22. Connect battery negative cable See: Starting and Charging/Battery/Battery Cable/Service and Repair/Battery Cables - Installation. 23. Bleed the base brake system See: Brakes and Traction Control/Brake Bleeding/Service and Repair. 24. Bleed clutch system See: Service and Repair. 25. Actuate clutch pedal a minimum of fifteen times to allow any air ingested into the system to vent to the master cylinder reservoir. 26. Install the air cleaner cover (3) and the air intake hose (2) to the hose (1) leading down the back of the engine. 27. Road test the vehicle to ensure proper operation of the clutch and brakes. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Description and Operation Clutch Slave Cylinder: Description and Operation DESCRIPTION The clutch slave cylinder (1) consists of a hydraulic piston and cylinder, seal and return spring. It is fastened to the transaxle bellhousing. The slave cylinder is connected to the clutch master cylinder hydraulic pipe, which is retained to the cylinder by a pair of retainer clips, and has a bleed port to facilitate the removal of air from the system. The clutch release system (1) utilizes a slave cylinder of a concentric design, having all components fixed about the same axis. The concentric slave cylinder (CSC) is mounted to the inside of the clutch bellhousing and is serviced only as an assembly. The concentric design permits high efficiency, resulting in low and consistent pedal effort, as well as automatic adjustment to compensate for clutch disc wear. The CSC is a self-contained unit, consisting of a main body (2) and piston (6), spring (5), integrated release bearing (1), and a rubber boot (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Clutch Slave Cylinder - Removal Clutch Slave Cylinder: Service and Repair Clutch Slave Cylinder - Removal REMOVAL WARNING: Chrysler does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on manual clutch parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris NOTE: To prevent drainage of clutch master cylinder assembly upon slave cylinder removal, it is necessary to make sure brake master cylinder fluid level is full and reservoir cap is installed tight. 1. Remove transaxle from vehicle See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/T355 Manual Transmission Removal. 2. Disconnect the clutch hydraulic line (6) from the bleeder assembly (2). 3. Disconnect and remove bleeder assembly (2) from the clutch master cylinder (3). 4. Remove the slave cylinder-to-clutch bellhousing bolts (4) and remove slave cylinder (3) from transaxle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Clutch Slave Cylinder - Removal > Page 3670 Clutch Slave Cylinder: Service and Repair Clutch Slave Cylinder - Installation INSTALLATION 1. Install slave cylinder (1) to transaxle using new bolts. NOTE: Torque three CSC body screws first, then torque the fluid tube attachment. 2. Torque slave cylinder-to-case bolts in three steps: - 2 Nm (18 in. lbs.) - 5 Nm (44 in. lbs.) - 8.4 Nm (74 in. lbs.) 3. Install transaxleSee: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/T355 Manual Transmission - Installation. 4. Bleed clutch hydraulic system. See: Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Clutch Pedal and Pad - Removal Clutch Pedal Assembly: Service and Repair Clutch Pedal and Pad - Removal REMOVAL CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water. NOTE: Before proceeding, See: Brakes and Traction Control/Service Precautions/Technician Safety Information See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings . 1. Remove engine cover. 2. Disconnect and isolate the battery negative cable from its post on the battery. 3. Remove the air cleaner cover (3) and the air intake hose (2) to the hose (1) leading down the back of the engine. 4. Remove the PCM bracket mounting nut (1) to upper shock tower stud (if equipped). 5. Remove the PCM bracket mounting bolt (2) to lower shock tower (if equipped). 6. Reposition the PCM and bracket (4) out of the way (if equipped). 7. Remove the master cylinder See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Brake Master Cylinder - Removal. 8. Remove the left front brake tube from the clip located on the left body rail. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Clutch Pedal and Pad - Removal > Page 3675 9. Disconnect the rear brake tubes (1) at the junction block (2). Install plugs at all of the open brake tubes. 10. Pull the tube bundle routing clip (with tubes) loose from the stud on the left side of the dash panel. 11. Remove the bolt (1) for the relay bracket (2) on the fuel filter (3) and reposition the relay out of the way of the brake booster (if equipped). 12. Disconnect the vacuum hose (2) from the check valve (1) on the power brake booster. Do not remove the check valve from power brake booster. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Clutch Pedal and Pad - Removal > Page 3676 13. Remove the steering column opening cover from the instrument panel. 14. Remove the steering column cover reinforcement mounting screws (2). Remove the steering column cover reinforcement (1) (if equipped). 15. Remove the stop lamp switch See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Removal. 16. Remove the retaining clip (2) securing the power brake booster push rod (1) to the brake pedal. To do so, position a small screwdriver under the center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin (3). Remove and discard the clip. Do not reuse the clip. 17. Slide the booster push rod (1) off the brake pedal pin (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Clutch Pedal and Pad - Removal > Page 3677 18. Remove the four nuts (4) attaching the power brake booster (3) to the dash panel. 19. Slide the power brake booster (3) forward until its mounting studs clear the dash panel, then remove it through the engine compartment. CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water. 20. Disconnect hydraulic tube (6) at the clutch master cylinder pressure line connector (5) by pulling retaining clip then pulling out on tube. Cap off hydraulic tube to prevent fluid loss. To completely drain clutch master cylinder and tubing, remove brake master cylinder cap and drain fluid into suitable container. 21. Disconnect clutch master cylinder pushrod (3) from clutch pedal. 22. Remove master cylinder assembly (4) from mounting position by turning 1/4 turn clockwise. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Clutch Pedal and Pad - Removal > Page 3678 23. Disconnect the clutch starter interlock switch connector (2). 24. Remove the four nuts (4) attaching the clutch pedal bracket assembly (1) to the dash panel. 25. Remove the clutch pedal bracket assembly (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Clutch Pedal and Pad - Removal > Page 3679 Clutch Pedal Assembly: Service and Repair Clutch Pedal and Pad - Installation INSTALLATION 1. Carefully install the clutch pedal bracket assembly (1) in the vehicle lining up the bracket with the clutch mounting studs on the dash panel. 2. Install the four nuts (4) attaching the clutch pedal bracket assembly (1) to the dash panel. 3. Tighten the four clutch pedal and bracket assembly mounting nuts (4) to 23 Nm (17 ft. lbs.). CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Clutch Pedal and Pad - Removal > Page 3680 4. Install clutch master cylinder body (4) to the clutch pedal bracket assembly and 1/4 turn counter clockwise to secure. 5. Insert hydraulic tube (6) into master cylinder pressure line connector (5) and install retaining clip. 6. Connect clutch master cylinder rod (3) to clutch pedal pin. An audible "click" should be heard. NOTE: Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs. 7. Install the power brake booster (3) by sliding the push rod and studs through the dash panel and into mounting position. 8. Under the instrument panel, install the four power brake booster mounting nuts (4). To tighten the nuts, refer to the following step. CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Clutch Pedal and Pad - Removal > Page 3681 9. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 Nm (17 ft. lbs.). 10. Using Mopar(R) Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster input rod (1). 11. Install the power brake booster push rod (1) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of the pin. Do not reuse the old clip. 12. Install and adjust the stop lamp switch in the brake pedal bracket See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Installation. 13. Install the steering column cover reinforcement (1) (if equipped) using the four mounting screws (2). 14. Install the steering column opening cover on the instrument panel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Clutch Pedal and Pad - Removal > Page 3682 CAUTION: When installing the vacuum hose on the check valve (1), make sure the hose is routed properly to avoid possible contact with unfriendly surfaces. 15. Connect the vacuum hose (2) to the vacuum check valve (1). 16. Install the relay bracket (2) to the fuel filter (3) using mounting bolt (1) (if equipped). 17. Install the tube bundle routing clip (with tubes) onto the stud on the left side of the dash panel. 18. Connect the rear brake tubes (1) to the junction block (2). Tighten the tube nuts to 17 Nm (150 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Clutch Pedal and Pad - Removal > Page 3683 19. Install the left front brake tube into the clip located on the left body rail. 20. Install the master cylinder See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Brake Master Cylinder - Installation. 21. Verify that brake master cylinder reservoir (1) is full. Top off with DOT 3 brake fluid if necessary. 22. Reposition the PCM and bracket (4) into mounting position (if equipped). 23. Install bolt (2) for the PCM mounting bracket to lower shock tower and tighten to 9 Nm (80 in. lbs.) (if equipped). 24. Install nut (1) for the PCM mounting bracket to upper shock tower stud and tighten to 9 Nm (80 in. lbs.) 9if equipped). 25. Connect battery negative cable See: Starting and Charging/Battery/Battery Cable/Service and Repair/Battery Cables - Installation. 26. Bleed the base brake system See: Brakes and Traction Control/Brake Bleeding/Service and Repair. 27. Bleed clutch system See: Service and Repair. 28. Actuate clutch pedal a minimum of fifteen times to allow any air ingested into the system to vent to the master cylinder reservoir. 29. Install the air cleaner cover (3) and the air intake hose (2) to the hose (1) leading down the back of the engine. 30. Road test the vehicle to ensure proper operation of the clutch and brakes. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Pressure Plate to Flywheel Bolts.......................................................................................................... .......................................................20 N.m (15 ft.lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Description and Operation > Modular Clutch Assembly - Description Pressure Plate: Description and Operation Modular Clutch Assembly - Description DESCRIPTION The modular clutch assembly (1) is located between the engine and manual transaxle in the transaxle bellhousing, and is responsible for transmitting engine power to the transaxle. The modular clutch is an assembly which incorporates a the following components: - Flywheel - Clutch Disc - Pressure Plate - Diaphragm Spring - Sensor - Cover Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Description and Operation > Modular Clutch Assembly - Description > Page 3689 Pressure Plate: Description and Operation Modular Clutch Assembly - Operation OPERATION The modular clutch assembly is designed to transmit power from the engine to the manual transaxle. This is accomplished by the friction and clamping force generated when the spring loaded pressure plate locks the clutch disc to the flywheel. The clutch disc, which is splined to the transaxle input shaft, transmits power until the center of the diaphragm spring is depressed, and the clamp force is removed from the disc. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Modular Clutch Assembly - Removal Pressure Plate: Service and Repair Modular Clutch Assembly - Removal REMOVAL WARNING: Chrysler does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on manual clutch parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris 1. Remove transaxle (3) from vehicle See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/T355 Manual Transmission - Removal. 2. Remove modular clutch assembly (1) from transaxle input shaft. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Modular Clutch Assembly - Removal > Page 3692 Pressure Plate: Service and Repair Modular Clutch Assembly - Inspection INSPECTION Fluid contamination is a frequent cause of clutch malfunctions. Oil, grease, water, or other fluids on the clutch contact surfaces will cause faulty operation. During inspection, note if any components are contaminated. Look for evidence of oil, grease, or water/road splash on clutch components. OIL CONTAMINATION Oil contamination indicates a leak at the rear main seal and/or transaxle input shaft. Oil leaks produce a residue of oil on the transaxle housing interior, clutch cover and flywheel. Heat buildup caused by slippage can bake the oil residue onto the components. This glaze-like residue ranges in color from amber to black. GREASE CONTAMINATION Grease contamination is usually a product of over-lubrication. During clutch service, apply only a small amount of grease to the input shaft splines. Excess grease may be thrown off during operation, contaminating the disc. ROAD SPLASH/WATER CONTAMINATION Road splash contamination is usually caused by driving the vehicle through deep water puddles. Water can be forced into the clutch housing, causing clutch components to become contaminated. Facing of disc will absorb moisture and bond to the flywheel and/or, pressure plate, if vehicle is allowed to stand for some time before use. If this condition occurs, replacement of clutch assembly may be required. Drive the vehicle until normal clutch operating temperature has been obtained. This will dry off disc assembly, pressure plate, and flywheel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > Modular Clutch Assembly - Removal > Page 3693 Pressure Plate: Service and Repair Modular Clutch Assembly - Installation INSTALLATION WARNING: Chrysler does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on manual clutch parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris 1. Install clutch module onto input shaft. 2. Install transaxle into vehicleSee: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/T355 Manual Transmission Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Actuators and Solenoids - CVT > Pressure Regulating Solenoid, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Actuators and Solenoids - CVT > Pressure Regulating Solenoid, CVT > Component Information > Locations > Page 3699 Pressure Regulating Solenoid: Diagrams Connector - (BODY) 22 WAY ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH - (BODY) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Actuators and Solenoids - CVT > Shift Solenoid, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Actuators and Solenoids - CVT > Shift Solenoid, CVT > Component Information > Locations > Page 3703 Shift Solenoid: Diagrams Connector - (BODY) 22 WAY ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH - (BODY) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Transmission Control Module C1 (CVT) (Body) 24 Way Control Module: Diagrams Transmission Control Module C1 (CVT) (Body) 24 Way Connector C1 (CVT) - (BODY) 24 WAY MODULE-TRANSMISSION CONTROL (CVT) - (BODY) 24 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Diagrams > Transmission Control Module C1 (CVT) (Body) 24 Way > Page 3708 Control Module: Diagrams Transmission Control Module C2 (CVT) (Body) 24 Way Connector C2 (CVT) - (BODY) 24 WAY MODULE-TRANSMISSION CONTROL (CVT) - (BODY) 24 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Description and Operation > Operation Control Module: Description and Operation Operation OPERATION Shift Control In order to select the gear ratio which can obtain the driving force in accordance with driver's intention and the vehicle condition, TCM monitors the driving conditions, such as the vehicle speed and the throttle position and selects the optimum gear ratio, and determines the gear change steps to the gear ratio. Then it sends the command to the stepping motor, and controls the flow-in/flow-out of line pressure to/from the primary pulley to determine the position of the moving-pulley and control the gear ratio. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 3711 Selection of the gear ratio is set for every position separately. "Drive" Position Shifting is available over all the ranges of gear ratios from the lowest to the highest. When using the Manual Mode (Vehicles with the manual mode) When the manual mode switch is turned ON, the fixed changing gear line is set. By moving the switch to + side or - side, shift change is like a M/T and selects from a range of 6 pre-programmed gear ranges. By limiting the shift to the area nearest the low side of the gear ratio, a larger driving force and engine brake are secured. Downhill Engine Brake Control When a downhill condition is detected while the accelerator pedal is released, the engine brake will be increased by downshifting so as to limit acceleration of the vehicle. Also, if uphill is detected, acceleration performance is improved by limiting the shift area on the highest side of the gear ratio. Acceleration Control According to vehicle speed and a increase of accelerator pedal angle, driver's request for acceleration as well as driving conditions are measured. At the time of starting or acceleration while moving, this function improves in acceleration feeling by making the engine speed proportionate to the vehicle speed. Even at the time of slower acceleration, a shift map which can gain a larger driving force is chosen for compatibility of mileage with drivability. Line Pressure and Secondary Pressure Control Control of line pressure and secondary pressure with a high degree of accuracy has reduced friction and improved fuel economy. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 3712 Normal Fluid Pressure Control The line pressure and the secondary pressure are optimized depending on driving conditions, on the basis of the throttle position, the engine speed, the primary pulley (input) revolution speed, the secondary pulley (output) revolution speed, the stop lamp SW signal, the PNP switch signal, the lock-up signal, the voltage, the target gear ratio, the fluid temperature, and the fluid pressure. Secondary Pressure Feedback Control When controlling the normal fluid pressure or the fluid pressure at the time of selection, the secondary pressure can be set more accurately by using the fluid pressure sensor to detect the secondary pressure and performing the feedback control. Lock-up Control The lock-up applied gear range has been expanded by locking up the torque converter at a lower vehicle speed than conventional A/T models. Selection Control When selecting between N (P) and D(R) position, the optimum operating pressure is set on the basis of the throttle position, the engine speed, and the secondary pulley (output) revolution speed to lessen the select shock. CAN Communication Real-time communications (signal exchanges) are maintained among the control units such as the CVT, C/U, ECM, combination meter etc. Each unit is controlled optimally depending on vehicle driving conditions while sharing information and in cooperating with the other control units. In CAN (Controller Area Network) communication, control units are connected with two communication lines (CAN-H line, CAN-L line) allowing a high rate of information to be transmitted by fewer wirings. Each control unit transmits/receives data but selectively reads required data only. Inputs and Outputs Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 3713 Engine/CVT Integration Control (CAN Communication Control) In order to improve gearshift feeling and to perform controls such as prevention of engine slowdown, engine power control signals are intercommunicated between the engine ECM and the TCM, and real-time cooperative controls depending on vehicle driving conditions are performed. TCM sends information such as fast slowdown signals, lock-up signals, torque down request signals to ECM, while receiving information such as torque down permission/prohibition signals, lock-up permission/prohibition signals, throttle position from ECM. Fail-safe Function If an unexpected signal is sent from any sensor, switch, solenoid etc., this function controls the CVT to make driving as smooth as possible. Secondary Speed Sensor The shift pattern is changed in accordance with throttle position when an unexpected signal is sent from the output speed sensor (secondary speed sensor) to the TCM. The manual mode position or the sports mode position is inhibited, and the transaxle is put in "D". Primary Speed Sensor The shift pattern is changed in accordance with throttle position and secondary speed (vehicle speed) when an unexpected signal is sent from the primary speed sensor to the TCM. The manual mode function or the sports mode function is inhibited, and the transaxle is put in "D". PNP Switch If an unexpected signal is sent from the PNP switch to the TCM, the transaxle is put in "D". Fluid Temperature Sensor If an unexpected signal is sent from the fluid temperature sensor to the TCM, the gear ratio obtained immediately before receiving the unexpected signal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 3714 is maintained and the gear ratio is controlled to keep engine speed under 5,000 rpm (approximately), depending on driving conditions. Secondary Pressure Sensor If an unexpected signal is sent from the secondary pressure sensor to the TCM, the secondary pressure feedback control is stopped and the offset value obtained immediately before the non-standard condition occurs is used to control line pressure. Line Pressure Solenoid If an unexpected condition of the solenoid is detected by the TCM, the line pressure solenoid is turned OFF to achieve the maximum fluid pressure. Secondary Pressure Solenoid If an unexpected condition of the secondary solenoid is detected by the TCM, the secondary pressure solenoid is turned OFF to achieve the maximum fluid pressure. Lock-up solenoid If an unexpected condition of the lock-up solenoid is detected by the TCM, the lock-up solenoid is turned OFF to cancel the lock-up. Stepping Motor If an unexpected condition of the stepping motor is detected by the TCM, the stepping motor coil phases "A" through "D" are all turned OFF to hold the gear ratio used immediately before the unexpected condition occurred. Lock-up/Selection Switching Solenoid If an unexpected condition of the solenoid is detected by the TCM, the lock-up/selection switching solenoid is turned OFF to cancel the lock-up. Backup Power Supply Transaxle assembly is protected by limiting the engine torque when the memory back-up power supply for controlling from the battery is not supplied to the TCM. Normal status is restored when turning the ignition switch OFF to ON after power is normally supplied TCM - 1. Shift control - 2. Line pressure control - 3. Selection control - 4. Lock-up control - 5. Engine/CVT integration control [CAN communication control] - 6. Self-diagnosis function - 7. Fail-safe function Primary Speed Sensor, Secondary Speed Sensor Primary Speed Sensor It is installed near the CVT fluid cooler in the transaxle case. It sends rotating speed of the primary pulley (input shaft) to the TCM as a pulse signal. Secondary Speed Sensor It is installed near the output gear part in the transaxle case. It sends rotating speed of the secondary pulley (output shaft) to the TCM as a pulse signal. TCM converts the pulse signal to vehicle speed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Service and Repair > Procedures Control Module: Procedures Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. TCM Initialization TRANSMISSION CONTROL MODULE INITIALIZATION NOTE: Refer to the following table when the Transmission Control Module (TCM) and/or transaxle has been replaced to determine if the TCM memory must be erased. INITIAL LEARN (BRAND-NEW MODULE, MEMORY ALREADY CLEAR) Battery must be connected. If the Totally Integrated Power Module (TIPM) is to be configured, configure the TIPM and then turn ignition key to OFF/LOCKED briefly, then back to RUN. The shifter must be in PARK or NEUTRAL, engine not running. 1. Turn the ignition key to RUN for 4 seconds to allow reading of new values. 2. Turn ignition key to OFF/LOCKED for 2 seconds to allow storing new values in EEROM. 3. Turn the ignition key to RUN, with scan tool clear DTCs. 4. Turn ignition key to OFF/LOCKED for 2 seconds. 5. After at least 7 seconds, read DTCs. 6. If DTCs resets See: Testing and Inspection RELEARN, AFTER REPLACING A TRANSAXLE 1. Turn ignition key to RUN. 2. Clear learning memory using the scan tool. 3. Turn the ignition key to OFF/LOCKED for 2 seconds. 4. Turn the ignition key to RUN Clear DTCs. 5. Turn the ignition key to OFF/LOCKED for 2 seconds. 6. Turn ignition key to RUN. 7. After at least 7 seconds, read DTCs. 8. If DTCs resets See: Testing and Inspection Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 3717 Control Module: Removal and Replacement Removal REMOVAL 1. The TCM (2) is located between the brake pedal bracket (1) and the left kick panel (3). 2. Unplug the two electrical connectors (2) at the TCM. 3. Remove the two nuts (1) that hold the TCM to the bulkhead. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 3718 4. Remove the TCM. Installation INSTALLATION 1. Install TCM mounting bracket holes (1) over the two studs on the bulkhead. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 3719 2. Install the two nuts to mounting studs (1) on the bulkhead and tighten to 15 Nm (130 in. lbs.). 3. Plug in electrical connectors (2) to TCM (3). NOTE: If a new TCM is installed a learn procedure must be performed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3725 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3730 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Specifications > Capacity Specifications Fluid - CVT: Capacity Specifications Automatic Transmission Fluid Capacity Service Fill ........................................................................................................................................... ..................................................... 7.0L ( 14.8 pints ) Overhaul Fill ..................................................... ......................................................................................................................................... 8.1L ( 17.1 pints ) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Specifications > Capacity Specifications > Page 3733 Fluid - CVT: Fluid Type Specifications Automatic Fluid .................................................................................................................................... ....................................................... Mopar CVTF+4 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Specifications > Page 3734 Fluid - CVT: Description and Operation TRANSMISSION FLUIDS NOTE: Refer to the maintenance schedules for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: All transaxles have a common transmission and differential sump. Filling the transaxle accommodates the differential as well. TRANSMISSION FLUIDS Mopar (R) CVT+4 is required in the CVT automatic transaxles. Mopar (R) CVT+4 when new is green in color. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. A dark brown/black fluid accompanied with a burnt odor and/or deterioration in shift quality may indicate fluid deterioration or transmission component failure. BG6 and T355 Manual transaxles require the use of Mopar (R) ATF+4 (Automatic Transmission Fluid). FLUID ADDITIVES Chrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various "special" additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of Chrysler and these additives must not be used. The use of transmission "sealers" should also be avoided, since they may adversely affect the integrity of transmission seals. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Testing and Inspection > Causes Of Burnt Fluid Fluid - CVT: Testing and Inspection Causes Of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. - Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. - A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. - Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Testing and Inspection > Causes Of Burnt Fluid > Page 3737 Fluid - CVT: Testing and Inspection Effects Of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Testing and Inspection > Causes Of Burnt Fluid > Page 3738 Fluid - CVT: Testing and Inspection Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid - failure to clean dipstick and fill tube when checking level - engine coolant entering the fluid - internal failure that generates debris - overheat that generates sludge (fluid breakdown) - failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Service and Repair > Check Oil Level Fluid - CVT: Service and Repair Check Oil Level CHECK OIL LEVEL 1. Verify that the vehicle is parked on a level surface. 2. Remove the dipstick tube cap. WARNING: There is a risk of accident from vehicle starting off by itself when engine is running. There is a risk of injury from contusions and burns if you insert your hands into the engine when it is started or when it is running. Secure vehicle to prevent it from moving off by itself. Wear properly fastened and close-fitting work clothes. Do not touch hot or rotating parts. 3. Actuate the service brake. Start engine and let it run at idle speed in selector lever position "P". 4. Shift through the transmission modes several times with the vehicle stationary and the engine idling. 5. Warm up the transmission, wait at least 2 minutes and check the oil level with the engine running. Push the Oil Dipstick 9336A into transmission fill tube until the dipstick tip contacts the oil pan and pull out again, read off oil level, repeat if necessary. NOTE: The dipstick will protrude from the fill tube when installed. CVT TRANSMISSION FILL GRAPH 6. Check transmission oil temperature using the appropriate scan tool. 7. The transmission Oil Dipstick 9336A has indicator marks every 10 mm. Determine the height of the oil level on the dipstick and using the height, the transmission temperature, and the Transmission Fluid Graph, determine if the transmission oil level is correct. 8. Add or remove oil as necessary and recheck the oil level. 9. Once the oil level is correct, install the dipstick tube cap. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Service and Repair > Check Oil Level > Page 3741 Fluid - CVT: Service and Repair Fluid And Strainer Service FLUID AND STRAINER SERVICE 1. Remove the bolts holding the oil pan (1) to the transaxle case. 2. Remove the oil pan from the transaxle case. 3. Remove the oil pan gasket (1) from the transaxle case. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Service and Repair > Check Oil Level > Page 3742 4. Remove the bolts holding the oil strainer (1) to the valve body. 5. Remove the oil strainer. 6. Remove and discard the oil strainer o-ring. CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring. 7. Install the new o-ring (1) onto the new oil strainer. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Service and Repair > Check Oil Level > Page 3743 8. Install the new oil strainer (1) onto the control valve assembly. Install and tighten the mounting bolts to 8 Nm (70 in. lbs.). CAUTION: Do not re-use the oil pan gasket. Remove any moisture, oil, and used gasket material from the surface where the new gasket is to be installed. When installing the oil pan gasket, align the dowel pin with the dowel pin hole in the oil pan gasket. 9. Install the oil pan gasket (1) onto the transaxle case. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Service and Repair > Check Oil Level > Page 3744 CAUTION: When installing the oil pan, align the dowel pin of the transaxle case with the dowel pin hole of the oil pan. 10. Install the oil pan on the transaxle case (1). Install and tighten the mounting bolts to 8 Nm (70 in.lbs.). NOTE: Only transmission fluid of the type labeled Mopar(R) CVTF+4 (Automatic Transmission Fluid) should be used in this transaxle. 11. Check the oil level See: Check Oil Level Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Service and Repair > Check Oil Level > Page 3745 Fluid - CVT: Service and Repair Transmission Cooler Filter Removal REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the left front tire. 3. Remove the left front splash shield. 4. Drain the coolant. 5. Remove the transmission lines (2) at the cooler (3). 6. Remove the coolant lines (1) at the cooler. 7. Remove the mounting bolts at the cooler. 8. Remove the cooler from the transmission. 9. Remove the fluid filter (1). Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Service and Repair > Check Oil Level > Page 3746 CAUTION: Apply CVT fluid on the seal part when installing the CVT fluid filter. 1. Install the CVT fluid filter (1) into the transaxle case. CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring. 2. Install the new o-ring (1) onto the CVT fluid filter. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Service and Repair > Check Oil Level > Page 3747 3. Install the CVT fluid cooler onto the transaxle case. 4. Install and tighten the mounting bolts to 4 Nm (37 in.lbs.). 5. Install the coolant lines (1) at the cooler. 6. Install the transmission lines (2) at the cooler (3). 7. Install the left front splash shield. 8. Install the left front tire. 9. Lower the hoist. 10. Top off coolant See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 11. Top off transmission fluid . See: Transmission Fill Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Service and Repair > Check Oil Level > Page 3748 Fluid - CVT: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Verify that the vehicle is parked on a level surface. 2. Remove the dipstick tube cap. 3. Add following initial quantity of MOPAR(R) CVTF+4, Automatic Transmission Fluid, to the transmission: a. If only fluid and filter were changed, add 7.0 L (14.8 pts.) of transmission fluid to transmission. b. If the transmission was completely overhauled or the torque converter was replaced or drained, add 8.1 L (17.1 pts.) of transmission fluid to transmission. 4. Check the transmission fluid See: Fluid And Strainer Service and adjust as required. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid Filter - CVT > Component Information > Service and Repair > Transmission Filter Fluid Filter - CVT: Service and Repair Transmission Filter FLUID AND STRAINER SERVICE 1. Remove the bolts holding the oil pan (1) to the transaxle case. 2. Remove the oil pan from the transaxle case. 3. Remove the oil pan gasket (1) from the transaxle case. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid Filter - CVT > Component Information > Service and Repair > Transmission Filter > Page 3753 4. Remove the bolts holding the oil strainer (1) to the valve body. 5. Remove the oil strainer. 6. Remove and discard the oil strainer o-ring. CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring. 7. Install the new o-ring (1) onto the new oil strainer. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid Filter - CVT > Component Information > Service and Repair > Transmission Filter > Page 3754 8. Install the new oil strainer (1) onto the control valve assembly. Install and tighten the mounting bolts to 8 Nm (70 in. lbs.). CAUTION: Do not re-use the oil pan gasket. Remove any moisture, oil, and used gasket material from the surface where the new gasket is to be installed. When installing the oil pan gasket, align the dowel pin with the dowel pin hole in the oil pan gasket. 9. Install the oil pan gasket (1) onto the transaxle case. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid Filter - CVT > Component Information > Service and Repair > Transmission Filter > Page 3755 CAUTION: When installing the oil pan, align the dowel pin of the transaxle case with the dowel pin hole of the oil pan. 10. Install the oil pan on the transaxle case (1). Install and tighten the mounting bolts to 8 Nm (70 in.lbs.). NOTE: Only transmission fluid of the type labeled Mopar(R) CVTF+4 (Automatic Transmission Fluid) should be used in this transaxle. 11. Check the oil level See: Service and Repair/Procedures/Check Oil Level Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid Filter - CVT > Component Information > Service and Repair > Transmission Filter > Page 3756 Fluid Filter - CVT: Service and Repair Transmission Cooler Filter Removal REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the left front tire. 3. Remove the left front splash shield. 4. Drain the coolant. 5. Remove the transmission lines (2) at the cooler (3). 6. Remove the coolant lines (1) at the cooler. 7. Remove the mounting bolts at the cooler. 8. Remove the cooler from the transmission. 9. Remove the fluid filter (1). Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid Filter - CVT > Component Information > Service and Repair > Transmission Filter > Page 3757 CAUTION: Apply CVT fluid on the seal part when installing the CVT fluid filter. 1. Install the CVT fluid filter (1) into the transaxle case. CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring. 2. Install the new o-ring (1) onto the CVT fluid filter. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid Filter - CVT > Component Information > Service and Repair > Transmission Filter > Page 3758 3. Install the CVT fluid cooler onto the transaxle case. 4. Install and tighten the mounting bolts to 4 Nm (37 in.lbs.). 5. Install the coolant lines (1) at the cooler. 6. Install the transmission lines (2) at the cooler (3). 7. Install the left front splash shield. 8. Install the left front tire. 9. Lower the hoist. 10. Top off coolant See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 11. Top off transmission fluid . See: Fluid - CVT/Service and Repair/Transmission Fill Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid Line/Hose, CVT > Component Information > Service and Repair Fluid Line/Hose: Service and Repair QUICK CONNECT FITTING DISASSEMBLY/ASSEMBLY DISCONNECT 1. Remove the dust cap by pulling it straight back off of the quick connect fitting (1). 2. Place the properly sized release tool (4) onto the transmission cooler line with the fingers of the tool facing the quick connect fitting. 3. Slide the release tool down the transmission line and engage the fingers of the tool into the retaining clip. When properly engaged in the clip, the tool will fit flush against the quick connect fitting. 4. Rotate the release tool 60° to expand the retaining clip. 5. While holding the release tool against the quick connect fitting, pull back on the transmission cooler line to remove it. 6. If the quick connect fitting is damaged or leaking at the transmission oil cooler or transmission, remove the fitting. CONNECT Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid Line/Hose, CVT > Component Information > Service and Repair > Page 3762 1. If removed, install the quick connect fitting into the transmission oil cooler or the transmission. Tighten the fitting to 15 Nm (132 in. lbs.). 2. Align the cooler line (3) with the quick connect fitting while pushing straight into the fitting. 3. Push in on the transmission cooler line until a clicks heard or felt. 4. Slide the dust cap (4) down the transmission cooler line and snap it over the quick connect fitting until it is fully seated and rotates freely. The dust cap will only snap over the quick connect fitting when the transmission cooler line is properly installed. NOTE: If the dust cap will not snap into place, repeat step 2. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid Pan, CVT > Component Information > Specifications Fluid Pan: Specifications Bolts, Oil Pan - to - Transaxle Case..................................................................................................... .........................................................8 N.m (70 in.lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations > Page 3769 Fluid Pressure Sensor/Switch: Diagrams Connector - (BODY) 22 WAY ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH - (BODY) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Pressure Regulating Solenoid, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Pressure Regulating Solenoid, CVT > Component Information > Locations > Page 3773 Pressure Regulating Solenoid: Diagrams Connector - (BODY) 22 WAY ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH - (BODY) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Transmission Control Module C1 (CVT) (Body) 24 Way Control Module: Diagrams Transmission Control Module C1 (CVT) (Body) 24 Way Connector C1 (CVT) - (BODY) 24 WAY MODULE-TRANSMISSION CONTROL (CVT) - (BODY) 24 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Transmission Control Module C1 (CVT) (Body) 24 Way > Page 3779 Control Module: Diagrams Transmission Control Module C2 (CVT) (Body) 24 Way Connector C2 (CVT) - (BODY) 24 WAY MODULE-TRANSMISSION CONTROL (CVT) - (BODY) 24 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation Control Module: Description and Operation Operation OPERATION Shift Control In order to select the gear ratio which can obtain the driving force in accordance with driver's intention and the vehicle condition, TCM monitors the driving conditions, such as the vehicle speed and the throttle position and selects the optimum gear ratio, and determines the gear change steps to the gear ratio. Then it sends the command to the stepping motor, and controls the flow-in/flow-out of line pressure to/from the primary pulley to determine the position of the moving-pulley and control the gear ratio. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 3782 Selection of the gear ratio is set for every position separately. "Drive" Position Shifting is available over all the ranges of gear ratios from the lowest to the highest. When using the Manual Mode (Vehicles with the manual mode) When the manual mode switch is turned ON, the fixed changing gear line is set. By moving the switch to + side or - side, shift change is like a M/T and selects from a range of 6 pre-programmed gear ranges. By limiting the shift to the area nearest the low side of the gear ratio, a larger driving force and engine brake are secured. Downhill Engine Brake Control When a downhill condition is detected while the accelerator pedal is released, the engine brake will be increased by downshifting so as to limit acceleration of the vehicle. Also, if uphill is detected, acceleration performance is improved by limiting the shift area on the highest side of the gear ratio. Acceleration Control According to vehicle speed and a increase of accelerator pedal angle, driver's request for acceleration as well as driving conditions are measured. At the time of starting or acceleration while moving, this function improves in acceleration feeling by making the engine speed proportionate to the vehicle speed. Even at the time of slower acceleration, a shift map which can gain a larger driving force is chosen for compatibility of mileage with drivability. Line Pressure and Secondary Pressure Control Control of line pressure and secondary pressure with a high degree of accuracy has reduced friction and improved fuel economy. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 3783 Normal Fluid Pressure Control The line pressure and the secondary pressure are optimized depending on driving conditions, on the basis of the throttle position, the engine speed, the primary pulley (input) revolution speed, the secondary pulley (output) revolution speed, the stop lamp SW signal, the PNP switch signal, the lock-up signal, the voltage, the target gear ratio, the fluid temperature, and the fluid pressure. Secondary Pressure Feedback Control When controlling the normal fluid pressure or the fluid pressure at the time of selection, the secondary pressure can be set more accurately by using the fluid pressure sensor to detect the secondary pressure and performing the feedback control. Lock-up Control The lock-up applied gear range has been expanded by locking up the torque converter at a lower vehicle speed than conventional A/T models. Selection Control When selecting between N (P) and D(R) position, the optimum operating pressure is set on the basis of the throttle position, the engine speed, and the secondary pulley (output) revolution speed to lessen the select shock. CAN Communication Real-time communications (signal exchanges) are maintained among the control units such as the CVT, C/U, ECM, combination meter etc. Each unit is controlled optimally depending on vehicle driving conditions while sharing information and in cooperating with the other control units. In CAN (Controller Area Network) communication, control units are connected with two communication lines (CAN-H line, CAN-L line) allowing a high rate of information to be transmitted by fewer wirings. Each control unit transmits/receives data but selectively reads required data only. Inputs and Outputs Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 3784 Engine/CVT Integration Control (CAN Communication Control) In order to improve gearshift feeling and to perform controls such as prevention of engine slowdown, engine power control signals are intercommunicated between the engine ECM and the TCM, and real-time cooperative controls depending on vehicle driving conditions are performed. TCM sends information such as fast slowdown signals, lock-up signals, torque down request signals to ECM, while receiving information such as torque down permission/prohibition signals, lock-up permission/prohibition signals, throttle position from ECM. Fail-safe Function If an unexpected signal is sent from any sensor, switch, solenoid etc., this function controls the CVT to make driving as smooth as possible. Secondary Speed Sensor The shift pattern is changed in accordance with throttle position when an unexpected signal is sent from the output speed sensor (secondary speed sensor) to the TCM. The manual mode position or the sports mode position is inhibited, and the transaxle is put in "D". Primary Speed Sensor The shift pattern is changed in accordance with throttle position and secondary speed (vehicle speed) when an unexpected signal is sent from the primary speed sensor to the TCM. The manual mode function or the sports mode function is inhibited, and the transaxle is put in "D". PNP Switch If an unexpected signal is sent from the PNP switch to the TCM, the transaxle is put in "D". Fluid Temperature Sensor If an unexpected signal is sent from the fluid temperature sensor to the TCM, the gear ratio obtained immediately before receiving the unexpected signal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 3785 is maintained and the gear ratio is controlled to keep engine speed under 5,000 rpm (approximately), depending on driving conditions. Secondary Pressure Sensor If an unexpected signal is sent from the secondary pressure sensor to the TCM, the secondary pressure feedback control is stopped and the offset value obtained immediately before the non-standard condition occurs is used to control line pressure. Line Pressure Solenoid If an unexpected condition of the solenoid is detected by the TCM, the line pressure solenoid is turned OFF to achieve the maximum fluid pressure. Secondary Pressure Solenoid If an unexpected condition of the secondary solenoid is detected by the TCM, the secondary pressure solenoid is turned OFF to achieve the maximum fluid pressure. Lock-up solenoid If an unexpected condition of the lock-up solenoid is detected by the TCM, the lock-up solenoid is turned OFF to cancel the lock-up. Stepping Motor If an unexpected condition of the stepping motor is detected by the TCM, the stepping motor coil phases "A" through "D" are all turned OFF to hold the gear ratio used immediately before the unexpected condition occurred. Lock-up/Selection Switching Solenoid If an unexpected condition of the solenoid is detected by the TCM, the lock-up/selection switching solenoid is turned OFF to cancel the lock-up. Backup Power Supply Transaxle assembly is protected by limiting the engine torque when the memory back-up power supply for controlling from the battery is not supplied to the TCM. Normal status is restored when turning the ignition switch OFF to ON after power is normally supplied TCM - 1. Shift control - 2. Line pressure control - 3. Selection control - 4. Lock-up control - 5. Engine/CVT integration control [CAN communication control] - 6. Self-diagnosis function - 7. Fail-safe function Primary Speed Sensor, Secondary Speed Sensor Primary Speed Sensor It is installed near the CVT fluid cooler in the transaxle case. It sends rotating speed of the primary pulley (input shaft) to the TCM as a pulse signal. Secondary Speed Sensor It is installed near the output gear part in the transaxle case. It sends rotating speed of the secondary pulley (output shaft) to the TCM as a pulse signal. TCM converts the pulse signal to vehicle speed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures Control Module: Procedures Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. TCM Initialization TRANSMISSION CONTROL MODULE INITIALIZATION NOTE: Refer to the following table when the Transmission Control Module (TCM) and/or transaxle has been replaced to determine if the TCM memory must be erased. INITIAL LEARN (BRAND-NEW MODULE, MEMORY ALREADY CLEAR) Battery must be connected. If the Totally Integrated Power Module (TIPM) is to be configured, configure the TIPM and then turn ignition key to OFF/LOCKED briefly, then back to RUN. The shifter must be in PARK or NEUTRAL, engine not running. 1. Turn the ignition key to RUN for 4 seconds to allow reading of new values. 2. Turn ignition key to OFF/LOCKED for 2 seconds to allow storing new values in EEROM. 3. Turn the ignition key to RUN, with scan tool clear DTCs. 4. Turn ignition key to OFF/LOCKED for 2 seconds. 5. After at least 7 seconds, read DTCs. 6. If DTCs resets See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Testing and Inspection RELEARN, AFTER REPLACING A TRANSAXLE 1. Turn ignition key to RUN. 2. Clear learning memory using the scan tool. 3. Turn the ignition key to OFF/LOCKED for 2 seconds. 4. Turn the ignition key to RUN Clear DTCs. 5. Turn the ignition key to OFF/LOCKED for 2 seconds. 6. Turn ignition key to RUN. 7. After at least 7 seconds, read DTCs. 8. If DTCs resets See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Testing and Inspection Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 3788 Control Module: Removal and Replacement Removal REMOVAL 1. The TCM (2) is located between the brake pedal bracket (1) and the left kick panel (3). 2. Unplug the two electrical connectors (2) at the TCM. 3. Remove the two nuts (1) that hold the TCM to the bulkhead. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 3789 4. Remove the TCM. Installation INSTALLATION 1. Install TCM mounting bracket holes (1) over the two studs on the bulkhead. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 3790 2. Install the two nuts to mounting studs (1) on the bulkhead and tighten to 15 Nm (130 in. lbs.). 3. Plug in electrical connectors (2) to TCM (3). NOTE: If a new TCM is installed a learn procedure must be performed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Seals and Gaskets, CVT > Component Information > Service and Repair > Left Axle Drive Shaft Seal - Installation Seals and Gaskets: Service and Repair Left Axle Drive Shaft Seal - Installation INSTALLATION 1. Install the left side differential oil seal using Installer 9871 (2) and Handle C-4171 (3). 2. Install halfshaft See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Half Shaft - Installation. 3. Road test vehicle and inspect for leaks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Seals and Gaskets, CVT > Component Information > Service and Repair > Left Axle Drive Shaft Seal - Installation > Page 3795 Seals and Gaskets: Service and Repair Right Axle Drive Shaft Seal - Installation INSTALLATION 1. Install the seal using Installer 9877(2) and Handle C-4171 (3). 2. Install Halfshaft See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Half Shaft - Installation. 3. Road test vehicle and inspect for leaks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Seals and Gaskets, CVT > Component Information > Service and Repair > Left Axle Drive Shaft Seal - Installation > Page 3796 Seals and Gaskets: Service and Repair Seal-Torque Converter Removal REMOVAL 1. Remove transmission See: Service and Repair/Removal and Replacement/Removal. 2. Remove torque converter. 3. Remove torque converter seal using Slide Hammer C-3752 and oil Seal Remover 9667. Installation INSTALLATION 1. Install torque converter seal using oil seal Installer 9858. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Seals and Gaskets, CVT > Component Information > Service and Repair > Left Axle Drive Shaft Seal - Installation > Page 3797 NOTE: Gauge Bar 6311 can be used for doing the following measurement. NOTE: When conducting measurements, measure two or more places and calculate the average value. 2. Install the torque converter on the transaxle and measure the dimension (1) to see if it is at least 13 mm. If the measurement is less than 13 mm, the torque converter is not fully installed. NOTE: Use the designated brand of CVT fluid. Use of other brands of CVT fluid other than the designated brand will deteriorate the driveability and the durability of the CVT, and will cause damage to the CVT. 3. Install the transmission See: Service and Repair/Removal and Replacement/Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors and Switches - CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors and Switches - CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations > Page 3802 Fluid Pressure Sensor/Switch: Diagrams Connector - (BODY) 22 WAY ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH - (BODY) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors and Switches - CVT > Transmission Speed Sensor, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Linkage, CVT > Component Information > Adjustments Shift Linkage: Adjustments ADJUSTMENT 1. Place TRS switch and selector lever in the PARK position. 2. Loosen the nut (4) that holds the shifter cable to the manual lever. 3. While pressing the manual lever towards the front of the vehicle in the PARK position direction, tighten the nut to 13 Nm (10 ft. lbs.). 4. Make sure that the park system is engaged when lever is placed in the PARK position. 5. Place the selector lever in PARK position and turn the ignition switch to on position (engine not running). 6. Make sure that the selector lever can be shifted to a different position other than PARK when the brake pedal is depressed. Also make sure the lever can be shifted from PARK only when the brake pedal is depressed. 7. Move and check for excessive effort, sticking, noise or rattle. 8. Confirm that the selector lever stops at each position with the feel of engagement when it is moved through all the positions. Check whether or not the actual position the selector lever is in matches the position shown by the shift position indicator and the transaxle valve body. 9. Confirm that the backup lamps illuminate only when the lever is placed in the REVERSE position. Confirm the backup lamps do not illuminate when the lever is placed in the PARK or NEUTRAL positions with the lever pushed against the REVERSE position. 10. Confirm the engine will only start when the lever is placed in the PARK or NEUTRAL positions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Linkage, CVT > Component Information > Service and Repair > Removal Shift Linkage: Service and Repair Removal REMOVAL 1. Remove the air box (1). 2. Disconnect the negative battery cable (2). 3. Remove shifter cable (2) at transmission bracket (3). 4. Remove the nut (4) on the shifter cable to shift lever. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Linkage, CVT > Component Information > Service and Repair > Removal > Page 3814 5. Remove the grommet (1) at the bulkhead. 6. Remove the shifterSee: Shifter CVT/Service and Repair/Removal. 7. Squeeze clip (2) at cable (1). 8. Pull cable from bracket (2) at bulkhead (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Linkage, CVT > Component Information > Service and Repair > Removal > Page 3815 9. Loosen the hold down bolts at the air bag module See: Relays and Modules/Relays and Modules - Restraint Systems/Air Bag Control Module/Service and Repair/Occupant Restraint Controller - Removal. 10. Pull the cable (1, 2) through the bulkhead into the engine compartment. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Linkage, CVT > Component Information > Service and Repair > Removal > Page 3816 Shift Linkage: Service and Repair Installation INSTALLATION 1. Install the shifter cable (1, 2) through the bulkhead and into the passenger compartment. 2. Install the cable into the bracket (2) at bulkhead (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Linkage, CVT > Component Information > Service and Repair > Removal > Page 3817 3. Insure that the cable clips into place. 4. Tighten the hold down bolts at the air bag module See: Relays and Modules/Relays and Modules - Restraint Systems/Air Bag Control Module/Service and Repair/Occupant Restraint Controller - Installation. 5. Install the shifterSee: Shifter CVT/Service and Repair/Installation. 6. Install the shifter cable grommet (1) at the bulkhead. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Linkage, CVT > Component Information > Service and Repair > Removal > Page 3818 7. Clip the cable (2) into the bracket (1) install the nut (4) over the shifter cable at the transmission shift lever See: Adjustments. 8. Connect the negative battery cable (2). 9. Install the air box (1) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Description and Operation Shift Interlock: Description and Operation DESCRIPTION The Shifter's serpentine pattern does not require the shifter to have a button on the knob to release it from "Park". There is a blocking lever within the Shifter that prevents undesired shifting out of "Park". The shifter has a solenoid which is actuated by depressing the brake pedal. This prevents shifting out of "Park" without the brake pedal being depressed. To operate the solenoid, the ignition must be in the "On" or "Run" position and the brake pedal must be depressed. The Brake Switch sends a signal to the Cabin Compartment Node (CCN) and the CCN, in turn, energizes the solenoid that moves the Park Lock Lever to allow the driver to shift out of 'Park". On the right side of the Console Pod is a plug that allows access to the Park Lock Lever for manual operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Description and Operation > Page 3822 Shift Interlock: Testing and Inspection SHIFT INTERLOCK CABLE The Interlock Cable is attached to a lever within the Shifter that prevents the Shift Lever from moving out of "Park" without the key (theft prevention). The Interlock Cable adjustment is preset at the factory. When properly adjusted, the Interlock System prevents the key being removed from the Key Cylinder when the Shift Lever is in a position other than "Park". Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Description and Operation > Page 3823 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Description and Operation > Page 3824 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Description and Operation > Page 3825 Shift Interlock: Adjustments ADJUSTMENT 1. Remove shift knob and shift bezel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Removal 2. Remove two screws (1). 3. Pull on side of housing (1) and unsnap housing tabs. 4. Disconnect console housing wire connector (2) and instrument panel connector (3). 5. Remove from vehicle. 6. Adjust interlock cable/system as follows:Pry up on cable adjuster lock to release and allow cable to "self-adjust". Lock cable adjustment by pressing down on the adjuster lock until bottomed at the cable housing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Service and Repair > Removal Shift Interlock: Service and Repair Removal REMOVAL 1. Disconnect the battery. 2. Remove the shifter bezel (1). 3. Remove the screws (1) at the console. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Service and Repair > Removal > Page 3828 4. Pull the console (1) back and remove electrical connector (2) (if equipped). 5. Remove the console (1). 6. Remove the bolts (1) at the shifter. 7. Separate the shift interlock cable from the shifter. 8. Remove lower shroud at steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Service and Repair > Removal > Page 3829 9. Place the ignition switch in the ON position. 10. Depress the clip on the shift interlock cable (2) and pull cable out of column (1). 11. Remove the cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Service and Repair > Removal > Page 3830 Shift Interlock: Service and Repair Installation INSTALLATION 1. Install the cable between the shifter and the steering column. 2. Clip the shift interlock cable to the shifter. 3. Install the shifter in place. 4. Install the shifter bolts and tighten to 70 Nm (52 ft. lbs.). 5. Install the console (1). 6. Connect the electrical connector (2) (if equipped). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Service and Repair > Removal > Page 3831 7. Install the screws (1) at the console. 8. Install the shifter bezel (1). 9. With the ignition switch in the ON position, push the interlock cable (2) into the column (1) until it clicks into place. 10. Check operation of the ignition-shift interlock feature. 11. Install the lower shroud. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Solenoid, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Solenoid, CVT > Component Information > Locations > Page 3835 Shift Solenoid: Diagrams Connector - (BODY) 22 WAY ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH - (BODY) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Locations Shifter CVT: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Locations > Page 3839 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Locations > Page 3840 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Diagrams > Shift Lever Assembly (Autostick) (Instrument Panel) 8 Way Shifter CVT: Diagrams Shift Lever Assembly (Autostick) (Instrument Panel) 8 Way Connector (AUTOSTICK) - (INSTRUMENT PANEL) 8 WAY ASSEMBLY-SHIFT LEVER (AUTOSTICK) - (INSTRUMENT PANEL) 8 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Diagrams > Shift Lever Assembly (Autostick) (Instrument Panel) 8 Way > Page 3843 Shifter CVT: Diagrams Shift Lever Assembly (Except Autostick) (Instrument Panel) 4 Way Connector (EXCEPT AUTOSTICK) - (INSTRUMENT PANEL) 4 WAY ASSEMBLY-SHIFT LEVER (EXCEPT AUTOSTICK) - (INSTRUMENT PANEL) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Service and Repair > Removal Shifter CVT: Service and Repair Removal REMOVAL 1. Remove shift knob and shift bezel.See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Removal See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Removal 2. Remove two screws (1). 3. Pull on side of housing (1) and unsnap housing tabs. 4. Disconnect console housing wire connector (2) and instrument panel connector (3). 5. Remove from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Service and Repair > Removal > Page 3846 6. Remove the bolts (1) at the shifter. 7. Separate the shift cable from the shifter. 8. Lift the shifter enough to gain access to electrical connector. 9. Unplug the electrical connector at the shifter. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Service and Repair > Removal > Page 3847 10. Remove the shifter. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Service and Repair > Removal > Page 3848 Shifter CVT: Service and Repair Installation INSTALLATION 1. Plug the electrical connector in at the shifter. 2. Install the shifter in place. 3. Clip the shift cable to the shifter. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter CVT > Component Information > Service and Repair > Removal > Page 3849 4. Install the shifter bolts and tighten to 70 Nm (52 ft. lbs.). 5. Place console housing (1) over shifter lever ensuring console tabs seat properly. 6. Install screws (1). 7. Replace shift bezel and knob.See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Description and Operation Transmission Cooler: Description and Operation DESCRIPTION The automatic transmission cooler is located in the front of the radiator and behind the front fascia and is combined with the A/C condenser. The transmission cooler is a heat exchanger that allows heat in the transmission fluid to be transferred to the air passing over the cooler fins. The Transmission oil cooler/A/C condenser assembly is equipped with quick connect fitting for the transmission oil cooler lines. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Service and Repair > Procedures Transmission Cooler: Procedures Cleaning CLEANING Check the external cooler for debris on the cooling fin surfaces. Clean as necessary. Inspection INSPECTION Inspect all hoses, tubes, clamps and connections for leaks, cracks, or damage. Replace as necessary. Use only approved transmission oil cooler hoses that are molded to fit the space available. Inspect external coolers for leaks, loose mounts, or damage. Replace as necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Service and Repair > Procedures > Page 3855 Transmission Cooler: Removal and Replacement Removal REMOVAL 1. On models equipped with A/C, refer to the A/C Condenser removal procedures. See: Heating and Air Conditioning/Condenser HVAC/Service and Repair/A/C Condenser - Removal 2. On non A/C equipped models, lift the vehicle and remove the lower closeout panel. 3. Using Tool 8875A disconnect the transmission cooler lines (1) from the transmission oil cooler (3). See: Fluid Line/Hose/Service and Repair 4. Remove the transmission oil cooler mounting bolts (2). 5. Remove the transmission oil cooler (3). Installation INSTALLATION 1. On models equipped with A/C, refer to the A/C Condenser installation procedure.See: Heating and Air Conditioning/Condenser HVAC/Service and Repair/A/C Condenser - Installation 2. On non A/C equipped models, position the transmission oil cooler (3) to the radiator. 3. Install the transmission oil cooler mounting bolts (2). Tighten the bolts to 8 Nm (70 in. lbs.). 4. Connect the transmission cooler lines to the transmission oil cooler (1). See: Fluid Line/Hose/Service and Repair 5. Install the lower closeout panel. 6. Lower the vehicle. 7. Start engine and check transmission fluid level. Adjust level as necessary. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Service and Repair > Procedures > Page 3856 1. Raise the vehicle on a hoist. 2. Remove the left front tire. 3. Remove the left front splash shield. 4. Drain the coolant. 5. Remove the transmission lines (2) at the cooler (3). 6. Remove the coolant lines (1) at the cooler. 7. Remove the mounting bolts at the cooler. 8. Remove the cooler from the transmission. 9. Remove the fluid filter (1). Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Service and Repair > Procedures > Page 3857 CAUTION: Apply CVT fluid on the seal part when installing the CVT fluid filter. 1. Install the CVT fluid filter (1) into the transaxle case. CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring. 2. Install the new o-ring (1) onto the CVT fluid filter. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Cooler, CVT > Component Information > Service and Repair > Procedures > Page 3858 3. Install the CVT fluid cooler onto the transaxle case. 4. Install and tighten the mounting bolts to 4 Nm (37 in.lbs.). 5. Install the coolant lines (1) at the cooler. 6. Install the transmission lines (2) at the cooler (3). 7. Install the left front splash shield. 8. Install the left front tire. 9. Lower the hoist. 10. Top off coolant See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 11. Top off transmission fluid . See: Fluid - CVT/Service and Repair/Transmission Fill Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Transmission Speed Sensor, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Description and Operation Valve Body: Description and Operation OPERATION Outline of the Functions of the Main Components Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Service and Repair > Removal and Replacement Valve Body: Removal and Replacement Removal REMOVAL 1. Remove the bolts holding the oil pan (1) to the transaxle case. 2. Remove the oil pan from the transaxle case. 3. Remove the oil pan gasket (1) from the transaxle case. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Service and Repair > Removal and Replacement > Page 3870 4. Remove the bolts holding the oil strainer (1) to the valve body. 5. Remove the oil strainer. 6. Remove and discard the oil strainer o-ring. 7. Remove the bolts holding the oil strainer bracket (1) to the valve body assembly. 8. Remove the oil strainer bracket from the valve body assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Service and Repair > Removal and Replacement > Page 3871 9. Remove the snap ring (1) from the terminal body (2). 10. Remove the nut holding the manual lever (1) to the manual shaft. 11. Remove the manual lever from the manual shaft. 12. To remove the control valve body assembly on to the transaxle case, fabricate a rod to set the pulley ratio linkage as shown. (1) 2 mm (0.08 in.) Diameter, (2) 80 mm (3 in.) long, (3) 30 mm (1 in.) long, (4) 50 mm (2 in.) long. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Service and Repair > Removal and Replacement > Page 3872 13. Install the rod into the linkage stopper hole (5) of the control valve assembly and secure under bolt head (3). 14. This sets the pulley ratio linkage (1) in position on the valve body (2). CAUTION: Tilt the valve body assembly away from the transaxle case on the manual shaft side to ease removal. Pay attention to completely remove the terminal body from the transaxle case. NOTE: Mounting bolt ( 7) is shorter than bolts (1). 15. Remove the mounting bolts (1) and (7) of the control valve body assembly. 16. Remove the valve body assembly from the transaxle case. Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Service and Repair > Removal and Replacement > Page 3873 INSTALLATION 1. To install the control valve body assembly on to the transaxle case, fabricate a rod to set the pulley ratio linkage as shown. (1) 2 mm (0.08 in.) Diameter, (2) 80 mm (3 in.) long, (3) 30 mm (1 in.) long, (4) 50 mm (2 in.) long. 2. Install the rod into the linkage stopper hole (5) of the control valve assembly and secure under bolt head (3). 3. This sets the pulley ratio linkage (1) in position on the valve body (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Service and Repair > Removal and Replacement > Page 3874 4. Position the locating tab (1) of the terminal body as shown and install the terminal body into the transaxle case. 5. Install the snap ring (1) onto the terminal body (2). 6. Install the control valve assembly (1) up from the bottom side and install it into the transaxle case. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Service and Repair > Removal and Replacement > Page 3875 7. Align the notch (1) of the pulley ratio linkage with the sheave position sensor (2). CAUTION: Apply CVT fluid when installing the bushing. 8. Install the bushing (1) into the control valve assembly. NOTE: Mounting bolt ( 7) is shorter than bolts (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Service and Repair > Removal and Replacement > Page 3876 9. Install and tighten the mounting bolts (1) and (7) of the control valve body assembly to 8 Nm (70 in. lbs). 10. Remove bolt (3) and remove the rod used to set the pulley ratio linkage (4). 11. Install bolt (3) and tighten to 8 Nm (70 in. lbs). 12. Install the manual lever (1) onto the manual shaft. Install and tighten the mounting nut to 22 Nm (16 in. lbs.). 13. Install the oil strainer bracket (1) onto the control valve assembly. Install and tighten the mounting bolts to 8 Nm (70 in. lbs.).onto the control valve assembly. Install and tighten the mounting bolts to 8 Nm (70 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Service and Repair > Removal and Replacement > Page 3877 CAUTION: Do not re-use the o-ring. Apply CVT fluid when installing the o-ring. 14. Install the new o-ring (1) onto the new oil strainer. 15. Install the new oil strainer (1) onto the control valve assembly. Install and tighten the mounting bolts to 8 Nm (70 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Service and Repair > Removal and Replacement > Page 3878 CAUTION: Do not re-use the oil pan gasket. Remove any moisture, oil, and used gasket material from the surface where the new gasket is to be installed. When installing the oil pan gasket, align the dowel pin with the dowel pin hole in the oil pan gasket. 16. Install the oil pan gasket (1) onto the transaxle case. CAUTION: When installing the oil pan, align the dowel pin of the transaxle case with the dowel pin hole of the oil pan. 17. Install the oil pan on the transaxle case (1). Install and tighten the mounting bolts to 8 Nm (70 in. lbs.). 18. Fill transmission with the required fluid. See: Service and Repair/Procedures/Transmission Fill Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Service and Repair > Removal and Replacement > Page 3879 Valve Body: Overhaul Disassembly DISASSEMBLY 1. Remove and discard the bushing (1) from the valve body. 2. Remove and discard the lip seal (1) from the transaxle case. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Service and Repair > Removal and Replacement > Page 3880 CAUTION: Do not drop the pulley ratio linkage. 3. Remove the pulley ratio linkage (1) from the valve body. 4. Remove the return spring (1) from the valve body. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Service and Repair > Removal and Replacement > Page 3881 CAUTION: Do not drop the manual valve. 5. Remove the manual valve (1) from the valve body. 6. Remove the valve body harness (1) from the valve body. 7. Remove the stepping motor (1) from the valve body. Assembly ASSEMBLY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Service and Repair > Removal and Replacement > Page 3882 CAUTION: Do not re-use the lip seal. Apply CVT fluid when installing the lip seal. 1. Install the new lip seal (1) into the transaxle case. 2. Install the stepping motor (1) onto the control valve body. Install and tighten the mounting bolts to 8 Nm (70 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Service and Repair > Removal and Replacement > Page 3883 3. Install the valve body harness (1) onto the control valve body. CAUTION: Ensure the manual valve is free of dirt, lint or other debris. Apply CVT fluid when installing the manual valve. 4. Install the manual valve (1) into the control valve body. 5. Install the return spring (1) into the control valve body. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve Body, CVT > Component Information > Service and Repair > Removal and Replacement > Page 3884 CAUTION: Apply CVT fluid when installing the pulley ratio linkage. 6. Hook the pawl of the pulley ratio linkage (1) onto the stepping motor and install it on the control valve. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3890 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Rear Drive Assembly (RDA) ................................................................................................................ ................................................ 500 ml (16.9 ounces) NOTE: Or fill to bottom of fill plug. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 3893 Fluid - Differential: Fluid Type Specifications Mopar Gear and Axle lubricant SAE 80W-90 API GL 5 or equivalent non-synthetic product. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Inner Boot - Removal Constant Velocity Joint Boot: Service and Repair Front Half Shaft, Inner Boot - Removal REMOVAL CAUTION: The inner tripod joints will use a retaining clip inside the housing to keep the spider assembly in the housing. Do not pull on the interconnecting shaft to disengage tripod housing from transmission stub shaft. Removal in this manner will cause damage to the inboard joint sealing boots. 1. Remove the halfshaft requiring boot replacement from the vehicle. See: Service and Repair/Half Shaft - Removal 2. Remove large boot clamp (2) that retains inner tripod joint sealing boot to tripod joint housing (3) and discard. Then remove small clamp (1) that retains inner tripod joint sealing boot to interconnecting shaft (5) and discard. Remove the sealing boot (4) from the tripod housing and slide it down the interconnecting shaft. CAUTION: When removing the spider joint from the tripod joint housing, hold the rollers in place on the spider trunnions to prevent the rollers and needle bearings from falling away. 3. Slide the interconnecting shaft and spider assembly (2) out of the tripod joint housing (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Inner Boot - Removal > Page 3900 4. Remove snap ring (3) that retains spider assembly (2) to interconnecting shaft (1). 5. Remove the spider assembly (1) from interconnecting shaft (4). If spider assembly will not come off interconnecting shaft by hand, it can be removed by tapping spider assembly with a brass drift (3). Do not hit the outer tripod bearings in an attempt to remove spider assembly from interconnecting shaft. 6. Slide sealing boot off interconnecting shaft. 7. Thoroughly clean and inspect spider assembly, tripod joint housing, and interconnecting shaft for any signs of excessive wear. If any parts show signs of excessive wear, the halfshaft assembly will require replacement. Component parts of these halfshaft assemblies are not serviceable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Inner Boot - Removal > Page 3901 Constant Velocity Joint Boot: Service and Repair Front Half Shaft, Inner Boot - Installation INSTALLATION NOTE: The inner tripod joint sealing boots are made from two different types of material. High-temperature applications (close to exhaust system) use silicone rubber whereas standard temperature applications use Hytrel plastic. The silicone sealing boots are soft and pliable. The Hytrel sealing boots are stiff and rigid. The replacement sealing boot MUST BE the same type of material as the sealing boot that was removed. 1. Slide inner tripod joint seal boot retaining clamp onto interconnecting shaft (4). Then slide the replacement inner tripod joint sealing boot (1) onto interconnecting shaft. Inner tripod joint seal boot MUST be positioned on interconnecting shaft, so the raised bead on the inside of the seal boot is in groove (3) on interconnecting shaft. NOTE: The rollers can fall off, use caution when installing the tripod 2. Install spider assembly (1) onto interconnecting shaft with chamfer (3) on spider assembly toward interconnecting shaft (2). 3. Spider assembly (2) must be installed on interconnecting shaft (3) far enough to fully install spider retaining snap ring. If spider assembly will not fully install on interconnecting shaft by hand, it can be installed by tapping the spider body with a brass drift (4). Do not hit the outer tripod bearings in an attempt to install spider assembly on interconnecting shaft. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Inner Boot - Removal > Page 3902 4. Install the spider assembly (2) to interconnecting shaft retaining snap ring (3) into groove on end of interconnecting shaft. Be sure the snap ring is fully seated into groove on interconnecting shaft (1). 5. Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing. Put the remaining amount into the sealing boot (3). 6. Align tripod housing (1) with spider assembly (2) and then slide tripod housing over spider assembly and interconnecting shaft. 7. Install inner tripod joint seal boot to interconnecting shaft clamp (3) evenly on sealing boot (4). 8. Clamp sealing boot onto interconnecting shaft using Clamp C-4975A and the following procedure. Place Clamp C-4975A over bridge of clamp. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Inner Boot - Removal > Page 3903 9. Tighten nut on Clamp C-4975A until jaws on tool are closed completely together (2), face to face. CAUTION: Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand. 10. Position sealing boot into the tripod (3) retaining groove. Install seal boot retaining clamp (2) evenly on sealing boot (1). CAUTION: The following positioning procedure determines the correct air pressure inside the inner tripod joint assembly prior to clamping the sealing boot to inner tripod joint housing. If this procedure is not done prior to clamping sealing boot to tripod joint housing, boot durability can be adversely affected. CAUTION: When venting the inner tripod joint assembly, use care so inner tripod sealing boot does not get punctured or, in any other way, damaged. If sealing boot is punctured or damaged while being vented, the sealing boot can not be used. 11. Insert a trim stick (4) between the tripod (3) and the sealing boot (1) to vent inner tripod joint assembly. When inserting trim stick between tripod housing and sealing boot, ensure trim stick is held flat and firmly against the tripod housing. If this is not done, damage to the sealing boot can occur. If inner tripod joint has a Hytrel (hard plastic) sealing boot, be sure trim stick is inserted between soft rubber insert and tripod housing, and not the hard plastic sealing boot and soft rubber insert. 12. With trim stick inserted between sealing boot (2) and tripod joint housing (4), position inner tripod joint on halfshaft until correct sealing boot Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Inner Boot - Removal > Page 3904 edge to edge length (1) is obtained for type of sealing boot material being used. Then remove the trim stick. 13. With trim stick inserted between sealing boot (2) and tripod housing (4), position inner tripod joint on halfshaft until correct sealing boot edge to edge length (1) is obtained for type of sealing boot material being used. Then remove the trim stick. 14. Clamp (1) tripod joint sealing boot (4) to tripod joint (2) using required procedure for type of boot clamp application. If seal boot uses crimp type boot clamp, clamp sealing boot onto tripod housing using Clamp C-4975A (3). Place Clamp C-4975A over bridge of clamp (1). 15. Tighten nut on Clamp C-4975A (3) until jaws on tool (3) are closed completely together (4), face-to-face. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Inner Boot - Removal > Page 3905 16. If seal boot (3) uses low profile latching type boot clamp, clamp sealing boot onto tripod housing using Clamping Tool, Snap-On(R) YA3050 (2) (or an equivalent). Place prongs of Clamp Locking Tool in the holes of the clamp (1). 17. Squeeze tool together until top band of clamp is latched behind the two tabs (2) on lower band of clamp. 18. Install the halfshaft requiring boot replacement back on the vehicle. See: Service and Repair/Half Shaft - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Inner Boot - Removal > Page 3906 Constant Velocity Joint Boot: Service and Repair Front Half Shaft, Outer Boot - Removal REMOVAL 1. Remove halfshaft assembly requiring boot replacement from vehicle. See: Service and Repair/Half Shaft - Removal 2. Remove large boot clamp (4) retaining CV joint sealing boot to CV joint housing (3) and discard. Remove small clamp (1) that retains outer CV joint sealing boot to interconnecting shaft (5) and discard. Remove sealing boot (2) from outer CV joint housing and slide it down interconnecting shaft. 3. Wipe away grease to expose outer CV joint and interconnecting shaft. 4. Remove outer CV joint from interconnecting shaft using the following procedure: Support interconnecting shaft in a vise equipped with protective caps on jaws of vise to prevent damage to interconnecting shaft. Then, using a soft-faced hammer (1), sharply hit the end of the CV joint housing to dislodge housing from internal circlip (3) on interconnecting shaft. Then slide outer CV joint off end of interconnecting shaft, joint may have to be tapped off shaft using a soft-faced hammer. 5. Remove large circlip (3) from the interconnecting shaft (2) before attempting to remove outer CV joint sealing boot. 6. Slide sealing boot off interconnecting shaft. 7. Thoroughly clean and inspect outer CV joint assembly and interconnecting joint for any signs of excessive wear. If any parts show signs of Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Inner Boot - Removal > Page 3907 excessive wear, the halfshaft assembly will require replacement. Component parts of these halfshaft assemblies are not serviceable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Inner Boot - Removal > Page 3908 Constant Velocity Joint Boot: Service and Repair Front Half Shaft, Outer Boot - Installation INSTALLATION 1. Slide new sealing boot clamp (2) onto interconnecting shaft (4). Slide the outer CV joint assembly sealing boot (1) onto the interconnecting shaft (4). Seal boot MUST be positioned on interconnecting shaft so the raised bead on the inside of the seal boot is in groove on interconnecting shaft. 2. Align splines on interconnecting shaft with splines on cross of outer CV joint assembly and start outer CV joint onto interconnecting shaft. 3. Install outer CV joint assembly onto interconnecting shaft by using a soft-faced hammer (1) and tapping end of stub axle (2) (with hub nut (4) installed) until outer CV joint (3) is fully seated on interconnecting shaft. 4. Outer CV joint assembly must be installed on interconnecting shaft until cross (2) of outer CV joint assembly (3) is seated against circlip on interconnecting shaft (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Inner Boot - Removal > Page 3909 5. Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into outer CV joint assembly housing. Put the remaining amount into the sealing boot (4). 6. Install outer CV joint sealing boot to interconnecting shaft clamp evenly on sealing boot. 7. Clamp sealing boot onto interconnecting shaft (2) using crimper, Clamp C-4975A and the following procedure. Place Clamp C-4975A (1) over bridge of clamp (3). 8. Tighten nut on Clamp C-4975A until jaws on tool are closed completely together (2), face to face. CAUTION: Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand. 9. Position outer CV joint sealing boot (4) into its retaining groove on outer CV joint housing. Install sealing boot to outer CV joint retaining clamp (1) evenly on sealing boot. 10. Clamp sealing boot onto outer CV joint housing using Clamp C-4975A (3) and the following procedure. Place Clamp C-4975A over bridge of clamp (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Half Shaft, Inner Boot - Removal > Page 3910 11. Tighten nut on Clamp C-4975A until jaws on tool are closed completely together (4), face to face. 12. Install the halfshaft requiring boot replacement back on the vehicle. See: Service and Repair/Half Shaft - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Description and Operation > Front Hub and Bearing - Description Wheel Bearing: Description and Operation Front Hub and Bearing - Description DESCRIPTION The wheel bearing (5) and hub (3) are pressed into the knuckle (1). The wheel bearing is secured in place using a snap ring. One side of the wheel bearing has an integrated magnetic encoder ring for wheel speed sensor usage as equipped. It is important that the wheel speed sensor magnetic encoder ring (dark band) (3) be positioned to the inside of the knuckle or the wheel speed sensor will not operate correctly. The wheel bearing is a Unit 1 type cartridge bearing that requires no maintenance. The wheel bearing can be serviced separately from the hub. The hub supports the driveline halfshaft outer constant velocity (C/V) joint. Each is splined and meshes in the center of the hub. The outer C/V joint is retained to the hub using a nut. The nut is locked to the outer C/V stub shaft using a cotter pin. The hub has five studs pressed into its flange. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Description and Operation > Front Hub and Bearing - Description > Page 3915 Wheel Bearing: Description and Operation Rear Hub and Bearing - Description DESCRIPTION The rear wheel bearing and wheel mounting hub used on this vehicle are a one-piece sealed unit or hub and bearing assembly. It is permanently lubricated when assembled and is sealed for life. There is no periodic lubrication or maintenance recommended for these units. The hub and bearing (5) is mounted to the trailing link (1). All vehicles have a magnetic encoder integrated into the right rear hub and bearing for speed sense. Vehicles equipped with antilock brakes have a magnetic encoder integrated into both rear hub and bearings. The encoder works with the rear wheel speed sensors to provide wheel speed signal. The sensor mounts by screw to the rear of the hub and bearing. The only serviceable components of the hub and bearing are the wheel mounting studs pressed into the hub. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front Hub and Bearing Wheel Bearing: Testing and Inspection Front Hub and Bearing WHEEL BEARING AND HUB NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weeping from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Testing and Inspection Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front Hub and Bearing > Page 3918 Wheel Bearing: Testing and Inspection Rear Hub and Bearing HUB AND BEARING NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub and bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Testing and Inspection Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal Wheel Bearing: Service and Repair Front Hub and Bearing - Removal REMOVAL NOTE: The removal and installation of the wheel bearing and hub from the knuckle is only to be done with the knuckle removed from the vehicle. 1. Remove the steering knuckle from the vehicle. See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair/Front Steering Knuckle - Removal 2. Position the knuckle support fixture 9712 as follows: a. For left side knuckles, place the locator block (2) to the left side (4) on the Fixture. The side of the locator block with the angle cut goes downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54 Nm (40 ft. lbs.). b. For right side knuckles, place the locator block (2) to the right side (3) on the Fixture. The side of the locator block with the angle cut goes downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54 Nm (40 ft. lbs.). 3. Install the knuckle in the Fixture as shown, guiding the steering arm (1) to rest on the locator block (3) and the brake caliper mounting bosses on the two Fixture pins (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 3921 4. Place the Fixture (3) with knuckle in an arbor press. 5. Position Remover/Installer 9712-2 (2), in the small end of the hub. Lower the arbor press ram (1) and remove the hub from the wheel bearing and knuckle. The bearing race will normally come out of the wheel bearing with the hub as it is pressed out of the bearing. 6. Remove the knuckle from the Fixture and turn it over. 7. Remove the snap ring (2) from the knuckle using an appropriate pair of snap ring pliers (1). 8. Place the knuckle back in the Fixture (3) in the arbor press ram. 9. Place Installer (2) MD-998334, on the outer race of the wheel bearing. Lower the arbor press ram (1) and remove the wheel bearing from the knuckle. 10. Remove the knuckle and tools from arbor press. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 3922 11. If the bearing race is still pressed onto the hub, install the Bearing Splitter (5), Special Tool 1130, between the hub flange and the bearing inner race (4). 12. Place the hub, bearing race and Bearing Splitter in an arbor press. The press support blocks must not obstruct the wheel hub while it is being pressed out of the bearing race. 13. Place Remover/Installer 9712-2 (2) in the end of the hub (3). Lower the arbor press ram (1) and remove the hub from the bearing race. NOTE: For installation, See: Front Hub and Bearing - Installation . Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 3923 Wheel Bearing: Service and Repair Front Hub and Bearing - Installation INSTALLATION CAUTION: When installing the wheel bearing (1) in the knuckle (2) it is important to place the side of bearing with the wheel speed sensor magnetic encoder ring (dark band) (3) in the knuckle first. Otherwise, the wheel speed sensor will not operate correctly. 1. Wipe the bearing bore of the knuckle clean of any grease or dirt with a clean, dry shop towel. 2. Place the knuckle in an arbor press supporting the knuckle from underneath using Cup 6310-1 (4.) 3. Place the NEW wheel bearing (5) magnetic encoder ring side down (see above Caution) into the bore of the knuckle. Be sure the wheel bearing is placed squarely into the bore. 4. Place Receiver 8498 (3), larger inside diameter end down over the outer race of the wheel bearing. 5. Place Disc 6310-2 (2) into top of Receiver 8498. Lower the arbor press ram (1) and press the wheel bearing into the knuckle until it is bottomed in the bore of the knuckle. 6. Remove the knuckle and tools from the arbor press. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 3924 7. Install a NEW snap ring (2) in the knuckle using an appropriate pair of snap ring pliers (1). Make sure the snap ring is fully seated. 8. Place the knuckle in an arbor press. Support the knuckle from underneath using Remover/Installer MB-990799 (3), smaller end up against the wheel bearing inner race. 9. Place the hub (4) in the wheel bearing making sure it is square with the bearing inner race. 10. Position Remover/Installer 9712-2 (2) in the end of the hub. Lower the arbor press ram (1) and press the hub into the wheel bearing until it bottoms. 11. Remove the knuckle and tools from the press. 12. Verify the hub turns smoothly without rubbing or binding. 13. Install the knuckle on the vehicle. See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair/Front Steering Knuckle Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 3925 Wheel Bearing: Service and Repair Rear Hub and Bearing - Removal REMOVAL NOTE: Before proceeding, See: Steering and Suspension/Suspension/Service Precautions/Vehicle Damage Warnings . 1. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. 3. Remove the disc brake caliper (2) lower guide pin bolt (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 3926 CAUTION: When moving rear brake caliper upward, use extreme care not to damage or overextend the flex hose. Damage may occur. 4. Rotate the caliper upward hinging off the upper guide pin bolt. Rotate the caliper upward just enough to allow brake rotor removal. Hang the caliper assembly in this position using wire or a bungee cord. 5. Remove any clips (2) retaining the brake rotor (3) to the wheel mounting studs. 6. Slide the brake rotor (3) off the hub and bearing (1). 7. Remove the screw (1) fastening the wheel speed sensor head (3) in the rear of the hub and bearing (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 3927 8. Remove the four bolts (1) securing the hub and bearing (2) to the trailing link. 9. Remove the hub and bearing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 3928 Wheel Bearing: Service and Repair Rear Hub and Bearing - Installation FRONT-WHEEL-DRIVE NOTE: If equipped, make sure the wheel speed sensor mount on the rear of the hub and bearing is directed toward the front of the vehicle. 1. Position the hub and bearing on the brake support plate and trailing link. 2. Install the four bolts (1) securing the hub and bearing (2) to the trailing link. Tighten the bolts to 105 Nm (77 ft. lbs.). NOTE: Before installing the wheel speed sensor head (3) into the rear of the hub and bearing (2), inspect the O-ring seal to make sure it is not dislodged, split, cut or damaged in any way. Replace the O-ring as necessary. 3. If equipped with a wheel speed sensor, install the wheel speed sensor head (3) into the rear of the hub and bearing (2). 4. If equipped with a wheel speed sensor, install the wheel speed sensor head mounting screw (1). Tighten the screw to 10 Nm (89 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 3929 5. Slide the brake rotor (3) over the parking brake shoes and onto the hub and bearing (1). 6. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 7. Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 60 Nm (44 ft. lbs.). 8. Install tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. 10. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving it. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Front Suspension Axle Nut: Specifications Front Suspension AXLE NUT Hub Nut................................................................................................................................................ ....................................................244 Nm (180 ft.lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Front Suspension > Page 3935 Axle Nut: Specifications Rear Suspension AXLE NUT Hub Nut................................................................................................................................................ ....................................................245 Nm (181 ft.lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications FLEX PLATE Flex Plate to Crankshaft-Bolts..........................................................................................................................29 Nm plus 51° turn (22 ft. lbs. plus 51° turn) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Flexplate - Removal Flex Plate: Service and Repair Flexplate - Removal REMOVAL 1. Remove transmission See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/T355 Manual Transmission Removal or See: Continuously Variable Transmission/Transaxle/Service and Repair/Removal and Replacement/Removal 2. Remove flex plate bolts (3) and discard. 3. Remove washer (2). 4. Remove flex plate (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Flexplate - Removal > Page 3941 Flex Plate: Service and Repair Flexplate - Installation INSTALLATION 1. Install flex plate (1). 2. Install washer (2). 3. Install new flex plate bolts (3) and tighten in a criss-cross pattern to 29 Nm (22 ft. lbs.) plus 51° rotation. 4. Install transaxle See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/T355 Manual Transmission - Installation or See: Continuously Variable Transmission/Transaxle/Service and Repair/Removal and Replacement/Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications FLYWHEEL/FLEXPLATE Flywheel to Crankshaft Bolts (except Turbo) ............................................................................................................................................ 95 Nm (70 ft.lbs.) Flywheel to Crankshaft Bolts (2.4L Turbo) ............................................................................................................................................. 133 Nm (98 ft.lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 3945 Flywheel: Description and Operation OPERATION The flywheel serves to dampen the engine firing pulses. The heavy weight of the flywheel relative to the rotating mass of the engine components serves to stabilize the flow of power to the remainder of the drivetrain. The crankshaft has the tendency to attempt to speed up and slow down in response to the cylinder firing pulses. The flywheel dampens these impulses by absorbing energy when the crankshaft speeds and releasing the energy back into the system when the crankshaft slows down. On a Dual Mass Flywheel, the additional secondary mass coupled to the transmission lowers the natural frequency of the transmission rotating elements. This decreases the transmission gear rattle. The damper springs between the two flywheel masses replace the clutch disc damper springs and assist in a smooth transfer of torque to the transmission. CAUTION: The Dual Mass Flywheel is serviced as an assembly only and should never be disassembled. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal Flywheel: Service and Repair Removal REMOVAL WARNING: Chrysler does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on manual clutch parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris 1. Remove transaxle See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/T355 Manual Transmission - Removal. 2. Remove clutch pressure plate and disc See: Clutch/Clutch Disc/Service and Repair/Removal and Replacement/Clutch Disc - Removal. 3. Remove the six flywheel-to-crankshaft bolts (3) and remove flywheel assembly (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal > Page 3948 Flywheel: Service and Repair Installation INSTALLATION WARNING: Chrysler does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on manual clutch parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris 1. Clean the surfaces of the flywheel and pressure plate to make certain that all oil, grease, and rust have been removed. 2. Install and torque the flywheel-to-crankshaft bolts to 95 Nm (70 ft.lbs.). 3. Install clutch pressure plate and disc See: Clutch/Clutch Disc/Service and Repair/Removal and Replacement/Clutch Disc - Installation. 4. Install transaxle assemblySee: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/T355 Manual Transmission Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3955 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3960 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications NV T355 .............................................................................................................................................. ......................................... 2.4 - 2.7 L ( 2.5 - 2.8 qts.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 3963 Fluid - M/T: Fluid Type Specifications Manual Fluid ........................................................................................................................................ ............................................ Mopar ATF+4 MS9602 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 3964 Fluid - M/T: Service and Repair FLUID DRAIN AND FILL NOTE: All T355 Manual Transaxles require the use of ATF+4 (Automatic Transmission Fluid). The transaxle fill plug (1) is located on the left side of the transaxle differential area. The fluid level should be within 3/16 inch from the bottom of the transaxle fill hole (vehicle must be level when checking). The transaxle drain plug (2) is located on the lower right side of the transaxle differential housing. Tighten drain plug to 14 Nm (120 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Axle Drive Shaft Seal - Removal Seals and Gaskets: Service and Repair Axle Drive Shaft Seal - Removal REMOVAL 1. Remove axle shaft. See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Half Shaft - Removal 2. Insert a flat-blade pry tool (2) at outer edge of axle shaft seal (1). 3. Tap on the pry tool (2) with a small hammer and remove axle shaft seal (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Axle Drive Shaft Seal - Removal > Page 3969 Seals and Gaskets: Service and Repair Axle Drive Shaft Seal - Installation INSTALLATION 1. Clean axle shaft seal bore of any excess sealant. 2. Align (bellhousing side) axle shaft seal with axle shaft seal bore. 3. Install axle seal on Seal Installer 9928 and Handle C-4171 and insert into axle shaft seal bore. 4. Tap seal into position until seated against transaxle case. 5. Align axle shaft seal with axle shaft seal bore. 6. Install (case side) axle seal on Seal Installer 9934 and Handle C-4171 and insert into axle shaft seal bore. 7. Tap seal into position until seated against transaxle case. 8. Install axle shaft. See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Half Shaft - Installation 9. Check transaxle fluid level and adjust as necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Axle Drive Shaft Seal - Removal > Page 3970 Seals and Gaskets: Service and Repair Axle Drive Shaft Seal - Removal REMOVAL 1. Remove axle shaft. See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Half Shaft - Removal 2. Insert a flat-blade pry tool (2) at outer edge of axle shaft seal (1). 3. Tap on the pry tool (2) with a small hammer and remove axle shaft seal (1). Axle Drive Shaft Seal - Installation INSTALLATION 1. Clean axle shaft seal bore of any excess sealant. 2. Align (bellhousing side) axle shaft seal with axle shaft seal bore. 3. Install axle seal on Seal Installer 9928 and Handle C-4171 and insert into axle shaft seal bore. 4. Tap seal into position until seated against transaxle case. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Axle Drive Shaft Seal - Removal > Page 3971 5. Align axle shaft seal with axle shaft seal bore. 6. Install (case side) axle seal on Seal Installer 9934 and Handle C-4171 and insert into axle shaft seal bore. 7. Tap seal into position until seated against transaxle case. 8. Install axle shaft. See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Half Shaft - Installation 9. Check transaxle fluid level and adjust as necessary. Input Shaft Seal - Removal REMOVAL 1. Remove the transaxle See: Service and Repair/Removal and Replacement/T355 Manual Transmission - Removal. 2. Remove seal. Input Shaft Seal - Installation INSTALLATION 1. Install input shaft seal (2) using installer 8864 (1). 2. Install the transaxleSee: Service and Repair/Removal and Replacement/T355 Manual Transmission - Installation. Shift Shaft Seals - Removal REMOVAL It is not necessary to remove the shift shafts from the transaxle to service the shift shaft seals. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair > Axle Drive Shaft Seal - Removal > Page 3972 1. Using a pick tool, pry up on the shift shaft seal, and remove seal from bore. Shift Shaft Seals - Installation INSTALLATION 1. Position new shift shaft seal into bore. 2. Install shift shaft seal into bore using an appropriate size deep-well socket. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation DESCRIPTION The Vehicle Speed Sensor (VSS) is a hall effect sensor mounted above the transaxle differential. The sensor is triggered by the ring gear teeth passing below it. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Vehicle Speed Sensor - Removal Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor - Removal REMOVAL 1. Open hood. 2. Remove the air cleaner housing.See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal 3. Disconnect the speed sensor connector. CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 4. Remove speed sensor retaining bolt. 5. Remove speed sensor from transaxle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Vehicle Speed Sensor - Removal > Page 3979 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor - Installation INSTALLATION 1. Using a NEW O-ring, install the speed sensor to the transaxle. 2. Install the bolt and tighten to 7 Nm (60 in. lbs.). 3. Connect speed sensor connector. 4. Install the air cleaner housing.See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Gearshift Boot - Removal Shifter M/T: Service and Repair Gearshift Boot - Removal REMOVAL 1. The gearshift knob or boot with a manual transmission is not removable. If the gear shift knob or boot are damaged the gearshift mechanism will need to be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Gearshift Boot - Removal > Page 3984 Shifter M/T: Service and Repair Gearshift Boot - Installation INSTALLATION 1. The gearshift knob or boot with a manual transmission is not removable. If the gear shift knob or boot are damaged the gearshift mechanism will need to be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Gearshift Boot - Removal > Page 3985 Shifter M/T: Service and Repair Gearshift Knob - Removal REMOVAL The gearshift knob or boot with a manual transmission is not removable. If the gear shift knob or boot are damaged the gearshift mechanism will need to be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Gearshift Boot - Removal > Page 3986 Shifter M/T: Service and Repair Gearshift Knob - Installation INSTALLATION The gearshift knob or boot with a manual transmission is not removable. If the gear shift knob or boot are damaged the gearshift mechanism will need to be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Gearshift Boot - Removal > Page 3987 Shifter M/T: Service and Repair Gearshift Boot - Removal REMOVAL 1. The gearshift knob or boot with a manual transmission is not removable. If the gear shift knob or boot are damaged the gearshift mechanism will need to be replaced. Gearshift Boot - Installation INSTALLATION 1. The gearshift knob or boot with a manual transmission is not removable. If the gear shift knob or boot are damaged the gearshift mechanism will need to be replaced. Gearshift Knob - Removal REMOVAL The gearshift knob or boot with a manual transmission is not removable. If the gear shift knob or boot are damaged the gearshift mechanism will need to be replaced. Gearshift Knob - Installation INSTALLATION The gearshift knob or boot with a manual transmission is not removable. If the gear shift knob or boot are damaged the gearshift mechanism will need to be replaced. Gearshift Mechanism - Removal REMOVAL 1. Remove gear shift bezel and turn the boot (1) inside out. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Gearshift Boot - Removal > Page 3988 2. Remove the center console assembly. Remove rear power window switch (if equipped) and disconnect harness from console. NOTE: Cable is pushed into a rubber grommet. 3. Remove select cable (2) from shift lever (1). 4. Remove shift cable retaining clip (3) and disconnect cable (2) from the shift lever (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Gearshift Boot - Removal > Page 3989 5. Remove the shifter assembly to riser bolts (3) and remove shifter from vehicle. Gearshift Mechanism - Installation INSTALLATION 1. Install shifter assembly to riser with boot (1) pulled inside out. Install and tighten bolts (3) to 7 Nm (61 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Gearshift Boot - Removal > Page 3990 2. Install shift cable (2) to shifter lever (1) and secure cable to shifter bracket with clip (3). 3. Install select cable to shifter lever and secure cable to shifter bracket. 4. Install center console assembly. Install rear power window switch (if equipped) and fasten harness to console. 5. Install gearshift boot. 6. Verify that shift pattern is aligned properly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Selector Shaft, M/T > Component Information > Service and Repair > Shift Selector Shaft Bushing(s) - Removal Selector Shaft: Service and Repair Shift Selector Shaft Bushing(s) - Removal REMOVAL 1. Install Slide Hammer C-3752 (1) through the select bushing. 2. Thread nut and washer onto slide hammer. 3. Using the slide hammer, remove the select shaft bushing (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Selector Shaft, M/T > Component Information > Service and Repair > Shift Selector Shaft Bushing(s) - Removal > Page 3996 Selector Shaft: Service and Repair Shift Selector Shaft Bushing(s) - Installation INSTALLATION 1. Position the replacement select shaft bushing over the crossover shaft bushing bore. 2. Using an appropriate size deep-well socket, install the select shaft bushing into the bushing bore. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Selector Shaft, M/T > Component Information > Service and Repair > Shift Selector Shaft Bushing(s) - Removal > Page 3997 Selector Shaft: Service and Repair Shift Shaft Bushing(s) - Removal REMOVAL 1. Remove shift shaft using procedure. 2. Thread Remover 6786 (1) into bushing. 3. Install slide hammer C-3752 (3) onto tool and remove bushing (2) using slide hammer . Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Selector Shaft, M/T > Component Information > Service and Repair > Shift Selector Shaft Bushing(s) - Removal > Page 3998 Selector Shaft: Service and Repair Shift Shaft Bushing(s) - Installation INSTALLATION 1. Position replacement bushing over shift shaft bore. 2. Using an appropriate size deep-well socket (1), install bushing (2) in selector shaft bore. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Selector Shaft, M/T > Component Information > Service and Repair > Shift Selector Shaft Bushing(s) - Removal > Page 3999 Selector Shaft: Service and Repair Shift Selector Shaft Bushing(s) - Removal REMOVAL 1. Install Slide Hammer C-3752 (1) through the select bushing. 2. Thread nut and washer onto slide hammer. 3. Using the slide hammer, remove the select shaft bushing (2). Shift Selector Shaft Bushing(s) - Installation INSTALLATION 1. Position the replacement select shaft bushing over the crossover shaft bushing bore. 2. Using an appropriate size deep-well socket, install the select shaft bushing into the bushing bore. Shift Shaft Bushing(s) - Removal REMOVAL 1. Remove shift shaft using procedure. 2. Thread Remover 6786 (1) into bushing. 3. Install slide hammer C-3752 (3) onto tool and remove bushing (2) using slide hammer Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Selector Shaft, M/T > Component Information > Service and Repair > Shift Selector Shaft Bushing(s) - Removal > Page 4000 . Shift Shaft Bushing(s) - Installation INSTALLATION 1. Position replacement bushing over shift shaft bore. 2. Using an appropriate size deep-well socket (1), install bushing (2) in selector shaft bore. Select Shaft - Removal REMOVAL 1. Disassemble transaxle. 2. With the transaxle disassembled, remove the select shaft seal. 3. Using snap-ring pliers, remove the snap ring (3) at the select shaft bore. 4. Push the select shaft (2) in the case and remove the select assembly. Select Shaft - Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Selector Shaft, M/T > Component Information > Service and Repair > Shift Selector Shaft Bushing(s) - Removal > Page 4001 1. Install select shaft to case and install snap ring (3). 2. Install the select shaft seal. 3. Assemble transaxle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > Gearshift Control Cable - Removal Shift Cable: Service and Repair Gearshift Control Cable - Removal REMOVAL 1. Remove the shifter See: Shifter M/T/Service and Repair/Gearshift Mechanism - Removal. 2. Raise hood. 3. Remove the resonator. 4. Remove engine cover. 5. Remove air cleaner assembly. 6. Disconnect both battery cables. See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery - Removal 7. Remove battery hold down clamp and bolt, and remove battery. 8. Remove battery tray. See: Starting and Charging/Battery/Battery Tray/Service and Repair/Battery Tray - Removal 9. Disconnect cables (1) from the shift levers at the transaxle (3). CAUTION: Pry up with equal force on both sides of shifter cable isolator bushings to avoid damaging cable isolator bushings. 10. Squeeze cable retaining clips (2) and remove cables from bracket (4). 11. Remove the Occupant Restraint Controller (ORC) See: Relays and Modules/Relays and Modules - Restraint Systems/Air Bag Control Module/Service and Repair/Occupant Restraint Controller - Removal. 12. Remove shifter See: Shifter M/T/Service and Repair/Gearshift Mechanism - Removal. 13. Squeeze cable retaining clips (2) and remove cables from bracket. 14. Remove cable assembly (1) from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Service and Repair > Gearshift Control Cable - Removal > Page 4006 Shift Cable: Service and Repair Gearshift Control Cable - Installation INSTALLATION CAUTION: Gearshift cable bushings must not be lubricated or the bushings will swell and split. 1. Install cable assembly through floor pan opening and secure to floor pan with grommet plate. 2. Route transaxle end of cable assembly into engine compartment and over transaxle assembly. 3. Connect cables (1) to the shift levers (3) at the transaxle. 4. Install cables (1) to bracket (4). 5. Install gearshift cables (1). 6. Install ORC See: Relays and Modules/Relays and Modules Restraint Systems/Air Bag Control Module/Service and Repair/Occupant Restraint Controller - Installation. 7. Install shifter See: Shifter M/T/Service and Repair/Gearshift Mechanism - Installation. 8. Install battery tray. 9. Install battery and hold-down clamp. 10. Install the air cleaner assembly. 11. Connect battery cables. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Rail, M/T > Component Information > Service and Repair > Shift Rail Bushing(s) - Removal Shift Rail: Service and Repair Shift Rail Bushing(s) - Removal REMOVAL 1. Thread Remover 6786 (1) into shift rail bushing. 2. Install slide hammer C-3752 (2) onto tool. 3. Remove bushing (3) using slide hammer and tool assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Rail, M/T > Component Information > Service and Repair > Shift Rail Bushing(s) - Removal > Page 4011 Shift Rail: Service and Repair Shift Rail Bushing(s) - Installation INSTALLATION 1. Line up replacement bushing in bore. 2. Using Installer MD998343, tap bushing into bore until flush with the chamfer in the case. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Rail, M/T > Component Information > Service and Repair > Shift Rail Bushing(s) - Removal > Page 4012 Shift Rail: Service and Repair Shift Shaft - Removal REMOVAL 1. Disassemble transaxle. 2. With the transaxle disassembled, remove the shift shaft by pushing on the shaft from the outside. Pull shaft out from the inside. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Rail, M/T > Component Information > Service and Repair > Shift Rail Bushing(s) - Removal > Page 4013 Shift Rail: Service and Repair Shift Shaft - Installation INSTALLATION 1. Pull shift shaft into position from the outside. 2. Assemble transaxle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation DESCRIPTION The Vehicle Speed Sensor (VSS) is a hall effect sensor mounted above the transaxle differential. The sensor is triggered by the ring gear teeth passing below it. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Vehicle Speed Sensor - Removal Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor - Removal REMOVAL 1. Open hood. 2. Remove the air cleaner housing.See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal 3. Disconnect the speed sensor connector. CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 4. Remove speed sensor retaining bolt. 5. Remove speed sensor from transaxle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Vehicle Speed Sensor - Removal > Page 4019 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor - Installation INSTALLATION 1. Using a NEW O-ring, install the speed sensor to the transaxle. 2. Install the bolt and tighten to 7 Nm (60 in. lbs.). 3. Connect speed sensor connector. 4. Install the air cleaner housing.See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Transmission Control Module C1 (CVT) (Body) 24 Way Control Module: Diagrams Transmission Control Module C1 (CVT) (Body) 24 Way Connector C1 (CVT) - (BODY) 24 WAY MODULE-TRANSMISSION CONTROL (CVT) - (BODY) 24 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Transmission Control Module C1 (CVT) (Body) 24 Way > Page 4026 Control Module: Diagrams Transmission Control Module C2 (CVT) (Body) 24 Way Connector C2 (CVT) - (BODY) 24 WAY MODULE-TRANSMISSION CONTROL (CVT) - (BODY) 24 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation Control Module: Description and Operation Operation OPERATION Shift Control In order to select the gear ratio which can obtain the driving force in accordance with driver's intention and the vehicle condition, TCM monitors the driving conditions, such as the vehicle speed and the throttle position and selects the optimum gear ratio, and determines the gear change steps to the gear ratio. Then it sends the command to the stepping motor, and controls the flow-in/flow-out of line pressure to/from the primary pulley to determine the position of the moving-pulley and control the gear ratio. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 4029 Selection of the gear ratio is set for every position separately. "Drive" Position Shifting is available over all the ranges of gear ratios from the lowest to the highest. When using the Manual Mode (Vehicles with the manual mode) When the manual mode switch is turned ON, the fixed changing gear line is set. By moving the switch to + side or - side, shift change is like a M/T and selects from a range of 6 pre-programmed gear ranges. By limiting the shift to the area nearest the low side of the gear ratio, a larger driving force and engine brake are secured. Downhill Engine Brake Control When a downhill condition is detected while the accelerator pedal is released, the engine brake will be increased by downshifting so as to limit acceleration of the vehicle. Also, if uphill is detected, acceleration performance is improved by limiting the shift area on the highest side of the gear ratio. Acceleration Control According to vehicle speed and a increase of accelerator pedal angle, driver's request for acceleration as well as driving conditions are measured. At the time of starting or acceleration while moving, this function improves in acceleration feeling by making the engine speed proportionate to the vehicle speed. Even at the time of slower acceleration, a shift map which can gain a larger driving force is chosen for compatibility of mileage with drivability. Line Pressure and Secondary Pressure Control Control of line pressure and secondary pressure with a high degree of accuracy has reduced friction and improved fuel economy. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 4030 Normal Fluid Pressure Control The line pressure and the secondary pressure are optimized depending on driving conditions, on the basis of the throttle position, the engine speed, the primary pulley (input) revolution speed, the secondary pulley (output) revolution speed, the stop lamp SW signal, the PNP switch signal, the lock-up signal, the voltage, the target gear ratio, the fluid temperature, and the fluid pressure. Secondary Pressure Feedback Control When controlling the normal fluid pressure or the fluid pressure at the time of selection, the secondary pressure can be set more accurately by using the fluid pressure sensor to detect the secondary pressure and performing the feedback control. Lock-up Control The lock-up applied gear range has been expanded by locking up the torque converter at a lower vehicle speed than conventional A/T models. Selection Control When selecting between N (P) and D(R) position, the optimum operating pressure is set on the basis of the throttle position, the engine speed, and the secondary pulley (output) revolution speed to lessen the select shock. CAN Communication Real-time communications (signal exchanges) are maintained among the control units such as the CVT, C/U, ECM, combination meter etc. Each unit is controlled optimally depending on vehicle driving conditions while sharing information and in cooperating with the other control units. In CAN (Controller Area Network) communication, control units are connected with two communication lines (CAN-H line, CAN-L line) allowing a high rate of information to be transmitted by fewer wirings. Each control unit transmits/receives data but selectively reads required data only. Inputs and Outputs Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 4031 Engine/CVT Integration Control (CAN Communication Control) In order to improve gearshift feeling and to perform controls such as prevention of engine slowdown, engine power control signals are intercommunicated between the engine ECM and the TCM, and real-time cooperative controls depending on vehicle driving conditions are performed. TCM sends information such as fast slowdown signals, lock-up signals, torque down request signals to ECM, while receiving information such as torque down permission/prohibition signals, lock-up permission/prohibition signals, throttle position from ECM. Fail-safe Function If an unexpected signal is sent from any sensor, switch, solenoid etc., this function controls the CVT to make driving as smooth as possible. Secondary Speed Sensor The shift pattern is changed in accordance with throttle position when an unexpected signal is sent from the output speed sensor (secondary speed sensor) to the TCM. The manual mode position or the sports mode position is inhibited, and the transaxle is put in "D". Primary Speed Sensor The shift pattern is changed in accordance with throttle position and secondary speed (vehicle speed) when an unexpected signal is sent from the primary speed sensor to the TCM. The manual mode function or the sports mode function is inhibited, and the transaxle is put in "D". PNP Switch If an unexpected signal is sent from the PNP switch to the TCM, the transaxle is put in "D". Fluid Temperature Sensor If an unexpected signal is sent from the fluid temperature sensor to the TCM, the gear ratio obtained immediately before receiving the unexpected signal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 4032 is maintained and the gear ratio is controlled to keep engine speed under 5,000 rpm (approximately), depending on driving conditions. Secondary Pressure Sensor If an unexpected signal is sent from the secondary pressure sensor to the TCM, the secondary pressure feedback control is stopped and the offset value obtained immediately before the non-standard condition occurs is used to control line pressure. Line Pressure Solenoid If an unexpected condition of the solenoid is detected by the TCM, the line pressure solenoid is turned OFF to achieve the maximum fluid pressure. Secondary Pressure Solenoid If an unexpected condition of the secondary solenoid is detected by the TCM, the secondary pressure solenoid is turned OFF to achieve the maximum fluid pressure. Lock-up solenoid If an unexpected condition of the lock-up solenoid is detected by the TCM, the lock-up solenoid is turned OFF to cancel the lock-up. Stepping Motor If an unexpected condition of the stepping motor is detected by the TCM, the stepping motor coil phases "A" through "D" are all turned OFF to hold the gear ratio used immediately before the unexpected condition occurred. Lock-up/Selection Switching Solenoid If an unexpected condition of the solenoid is detected by the TCM, the lock-up/selection switching solenoid is turned OFF to cancel the lock-up. Backup Power Supply Transaxle assembly is protected by limiting the engine torque when the memory back-up power supply for controlling from the battery is not supplied to the TCM. Normal status is restored when turning the ignition switch OFF to ON after power is normally supplied TCM - 1. Shift control - 2. Line pressure control - 3. Selection control - 4. Lock-up control - 5. Engine/CVT integration control [CAN communication control] - 6. Self-diagnosis function - 7. Fail-safe function Primary Speed Sensor, Secondary Speed Sensor Primary Speed Sensor It is installed near the CVT fluid cooler in the transaxle case. It sends rotating speed of the primary pulley (input shaft) to the TCM as a pulse signal. Secondary Speed Sensor It is installed near the output gear part in the transaxle case. It sends rotating speed of the secondary pulley (output shaft) to the TCM as a pulse signal. TCM converts the pulse signal to vehicle speed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures Control Module: Procedures Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. TCM Initialization TRANSMISSION CONTROL MODULE INITIALIZATION NOTE: Refer to the following table when the Transmission Control Module (TCM) and/or transaxle has been replaced to determine if the TCM memory must be erased. INITIAL LEARN (BRAND-NEW MODULE, MEMORY ALREADY CLEAR) Battery must be connected. If the Totally Integrated Power Module (TIPM) is to be configured, configure the TIPM and then turn ignition key to OFF/LOCKED briefly, then back to RUN. The shifter must be in PARK or NEUTRAL, engine not running. 1. Turn the ignition key to RUN for 4 seconds to allow reading of new values. 2. Turn ignition key to OFF/LOCKED for 2 seconds to allow storing new values in EEROM. 3. Turn the ignition key to RUN, with scan tool clear DTCs. 4. Turn ignition key to OFF/LOCKED for 2 seconds. 5. After at least 7 seconds, read DTCs. 6. If DTCs resets See: Continuously Variable Transmission/Transaxle/Testing and Inspection RELEARN, AFTER REPLACING A TRANSAXLE 1. Turn ignition key to RUN. 2. Clear learning memory using the scan tool. 3. Turn the ignition key to OFF/LOCKED for 2 seconds. 4. Turn the ignition key to RUN Clear DTCs. 5. Turn the ignition key to OFF/LOCKED for 2 seconds. 6. Turn ignition key to RUN. 7. After at least 7 seconds, read DTCs. 8. If DTCs resets See: Continuously Variable Transmission/Transaxle/Testing and Inspection Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 4035 Control Module: Removal and Replacement Removal REMOVAL 1. The TCM (2) is located between the brake pedal bracket (1) and the left kick panel (3). 2. Unplug the two electrical connectors (2) at the TCM. 3. Remove the two nuts (1) that hold the TCM to the bulkhead. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 4036 4. Remove the TCM. Installation INSTALLATION 1. Install TCM mounting bracket holes (1) over the two studs on the bulkhead. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 4037 2. Install the two nuts to mounting studs (1) on the bulkhead and tighten to 15 Nm (130 in. lbs.). 3. Plug in electrical connectors (2) to TCM (3). NOTE: If a new TCM is installed a learn procedure must be performed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4042 Control Module: Diagrams Connector (AWD) - (BODY) 16 WAY MODULE-ALL WHEEL DRIVE CONTROL (AWD) - (BODY) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations > Page 4048 Fluid Pressure Sensor/Switch: Diagrams Connector - (BODY) 22 WAY ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH - (BODY) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Speed Sensor, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation DESCRIPTION The Vehicle Speed Sensor (VSS) is a hall effect sensor mounted above the transaxle differential. The sensor is triggered by the ring gear teeth passing below it. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Vehicle Speed Sensor - Removal Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor - Removal REMOVAL 1. Open hood. 2. Remove the air cleaner housing.See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal 3. Disconnect the speed sensor connector. CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 4. Remove speed sensor retaining bolt. 5. Remove speed sensor from transaxle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Vehicle Speed Sensor - Removal > Page 4061 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor - Installation INSTALLATION 1. Using a NEW O-ring, install the speed sensor to the transaxle. 2. Install the bolt and tighten to 7 Nm (60 in. lbs.). 3. Connect speed sensor connector. 4. Install the air cleaner housing.See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4066 Control Module: Diagrams Connector (AWD) - (BODY) 16 WAY MODULE-ALL WHEEL DRIVE CONTROL (AWD) - (BODY) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4072 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4077 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Power Transfer Unit (PTU) .................................................................................................................. ................................................ 540 ml (18.2 ounces) NOTE: Or fill to bottom of fill plug. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 4080 Fluid - Transfer Case: Fluid Type Specifications Mopar Gear and Axle lubricant SAE 80W-90 API GL 5 or equivalent non-synthetic product. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4085 Control Module: Diagrams Connector (AWD) - (BODY) 16 WAY MODULE-ALL WHEEL DRIVE CONTROL (AWD) - (BODY) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - CVT > Pressure Regulating Solenoid, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - CVT > Pressure Regulating Solenoid, CVT > Component Information > Locations > Page 4092 Pressure Regulating Solenoid: Diagrams Connector - (BODY) 22 WAY ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH - (BODY) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - CVT > Shift Solenoid, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - CVT > Shift Solenoid, CVT > Component Information > Locations > Page 4096 Shift Solenoid: Diagrams Connector - (BODY) 22 WAY ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH - (BODY) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Transmission Control Module C1 (CVT) (Body) 24 Way Control Module: Diagrams Transmission Control Module C1 (CVT) (Body) 24 Way Connector C1 (CVT) - (BODY) 24 WAY MODULE-TRANSMISSION CONTROL (CVT) - (BODY) 24 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Diagrams > Transmission Control Module C1 (CVT) (Body) 24 Way > Page 4103 Control Module: Diagrams Transmission Control Module C2 (CVT) (Body) 24 Way Connector C2 (CVT) - (BODY) 24 WAY MODULE-TRANSMISSION CONTROL (CVT) - (BODY) 24 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation Control Module: Description and Operation Operation OPERATION Shift Control In order to select the gear ratio which can obtain the driving force in accordance with driver's intention and the vehicle condition, TCM monitors the driving conditions, such as the vehicle speed and the throttle position and selects the optimum gear ratio, and determines the gear change steps to the gear ratio. Then it sends the command to the stepping motor, and controls the flow-in/flow-out of line pressure to/from the primary pulley to determine the position of the moving-pulley and control the gear ratio. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 4106 Selection of the gear ratio is set for every position separately. "Drive" Position Shifting is available over all the ranges of gear ratios from the lowest to the highest. When using the Manual Mode (Vehicles with the manual mode) When the manual mode switch is turned ON, the fixed changing gear line is set. By moving the switch to + side or - side, shift change is like a M/T and selects from a range of 6 pre-programmed gear ranges. By limiting the shift to the area nearest the low side of the gear ratio, a larger driving force and engine brake are secured. Downhill Engine Brake Control When a downhill condition is detected while the accelerator pedal is released, the engine brake will be increased by downshifting so as to limit acceleration of the vehicle. Also, if uphill is detected, acceleration performance is improved by limiting the shift area on the highest side of the gear ratio. Acceleration Control According to vehicle speed and a increase of accelerator pedal angle, driver's request for acceleration as well as driving conditions are measured. At the time of starting or acceleration while moving, this function improves in acceleration feeling by making the engine speed proportionate to the vehicle speed. Even at the time of slower acceleration, a shift map which can gain a larger driving force is chosen for compatibility of mileage with drivability. Line Pressure and Secondary Pressure Control Control of line pressure and secondary pressure with a high degree of accuracy has reduced friction and improved fuel economy. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 4107 Normal Fluid Pressure Control The line pressure and the secondary pressure are optimized depending on driving conditions, on the basis of the throttle position, the engine speed, the primary pulley (input) revolution speed, the secondary pulley (output) revolution speed, the stop lamp SW signal, the PNP switch signal, the lock-up signal, the voltage, the target gear ratio, the fluid temperature, and the fluid pressure. Secondary Pressure Feedback Control When controlling the normal fluid pressure or the fluid pressure at the time of selection, the secondary pressure can be set more accurately by using the fluid pressure sensor to detect the secondary pressure and performing the feedback control. Lock-up Control The lock-up applied gear range has been expanded by locking up the torque converter at a lower vehicle speed than conventional A/T models. Selection Control When selecting between N (P) and D(R) position, the optimum operating pressure is set on the basis of the throttle position, the engine speed, and the secondary pulley (output) revolution speed to lessen the select shock. CAN Communication Real-time communications (signal exchanges) are maintained among the control units such as the CVT, C/U, ECM, combination meter etc. Each unit is controlled optimally depending on vehicle driving conditions while sharing information and in cooperating with the other control units. In CAN (Controller Area Network) communication, control units are connected with two communication lines (CAN-H line, CAN-L line) allowing a high rate of information to be transmitted by fewer wirings. Each control unit transmits/receives data but selectively reads required data only. Inputs and Outputs Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 4108 Engine/CVT Integration Control (CAN Communication Control) In order to improve gearshift feeling and to perform controls such as prevention of engine slowdown, engine power control signals are intercommunicated between the engine ECM and the TCM, and real-time cooperative controls depending on vehicle driving conditions are performed. TCM sends information such as fast slowdown signals, lock-up signals, torque down request signals to ECM, while receiving information such as torque down permission/prohibition signals, lock-up permission/prohibition signals, throttle position from ECM. Fail-safe Function If an unexpected signal is sent from any sensor, switch, solenoid etc., this function controls the CVT to make driving as smooth as possible. Secondary Speed Sensor The shift pattern is changed in accordance with throttle position when an unexpected signal is sent from the output speed sensor (secondary speed sensor) to the TCM. The manual mode position or the sports mode position is inhibited, and the transaxle is put in "D". Primary Speed Sensor The shift pattern is changed in accordance with throttle position and secondary speed (vehicle speed) when an unexpected signal is sent from the primary speed sensor to the TCM. The manual mode function or the sports mode function is inhibited, and the transaxle is put in "D". PNP Switch If an unexpected signal is sent from the PNP switch to the TCM, the transaxle is put in "D". Fluid Temperature Sensor If an unexpected signal is sent from the fluid temperature sensor to the TCM, the gear ratio obtained immediately before receiving the unexpected signal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Operation > Page 4109 is maintained and the gear ratio is controlled to keep engine speed under 5,000 rpm (approximately), depending on driving conditions. Secondary Pressure Sensor If an unexpected signal is sent from the secondary pressure sensor to the TCM, the secondary pressure feedback control is stopped and the offset value obtained immediately before the non-standard condition occurs is used to control line pressure. Line Pressure Solenoid If an unexpected condition of the solenoid is detected by the TCM, the line pressure solenoid is turned OFF to achieve the maximum fluid pressure. Secondary Pressure Solenoid If an unexpected condition of the secondary solenoid is detected by the TCM, the secondary pressure solenoid is turned OFF to achieve the maximum fluid pressure. Lock-up solenoid If an unexpected condition of the lock-up solenoid is detected by the TCM, the lock-up solenoid is turned OFF to cancel the lock-up. Stepping Motor If an unexpected condition of the stepping motor is detected by the TCM, the stepping motor coil phases "A" through "D" are all turned OFF to hold the gear ratio used immediately before the unexpected condition occurred. Lock-up/Selection Switching Solenoid If an unexpected condition of the solenoid is detected by the TCM, the lock-up/selection switching solenoid is turned OFF to cancel the lock-up. Backup Power Supply Transaxle assembly is protected by limiting the engine torque when the memory back-up power supply for controlling from the battery is not supplied to the TCM. Normal status is restored when turning the ignition switch OFF to ON after power is normally supplied TCM - 1. Shift control - 2. Line pressure control - 3. Selection control - 4. Lock-up control - 5. Engine/CVT integration control [CAN communication control] - 6. Self-diagnosis function - 7. Fail-safe function Primary Speed Sensor, Secondary Speed Sensor Primary Speed Sensor It is installed near the CVT fluid cooler in the transaxle case. It sends rotating speed of the primary pulley (input shaft) to the TCM as a pulse signal. Secondary Speed Sensor It is installed near the output gear part in the transaxle case. It sends rotating speed of the secondary pulley (output shaft) to the TCM as a pulse signal. TCM converts the pulse signal to vehicle speed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures Control Module: Procedures Pinion Factor Setting PINION FACTOR SETTING NOTE: This procedure must be performed if the PCM has been replaced with a NEW or replacement unit. Failure to perform this procedure will result in an inoperative or improperly calibrated speedometer. The vehicle speed readings for the speedometer are taken from the output speed sensor. The PCM must be calibrated to the different combinations of equipment (final drive and tires) available. Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. 1. Plug the scan tool into the diagnostic connector located under the instrument panel. 2. Select the Transmission menu. 3. Select the Miscellaneous menu. 4. Select Pinion Factor. Then follow the instructions on the scan tool screen. TCM Initialization TRANSMISSION CONTROL MODULE INITIALIZATION NOTE: Refer to the following table when the Transmission Control Module (TCM) and/or transaxle has been replaced to determine if the TCM memory must be erased. INITIAL LEARN (BRAND-NEW MODULE, MEMORY ALREADY CLEAR) Battery must be connected. If the Totally Integrated Power Module (TIPM) is to be configured, configure the TIPM and then turn ignition key to OFF/LOCKED briefly, then back to RUN. The shifter must be in PARK or NEUTRAL, engine not running. 1. Turn the ignition key to RUN for 4 seconds to allow reading of new values. 2. Turn ignition key to OFF/LOCKED for 2 seconds to allow storing new values in EEROM. 3. Turn the ignition key to RUN, with scan tool clear DTCs. 4. Turn ignition key to OFF/LOCKED for 2 seconds. 5. After at least 7 seconds, read DTCs. 6. If DTCs resets See: Continuously Variable Transmission/Transaxle/Testing and Inspection RELEARN, AFTER REPLACING A TRANSAXLE 1. Turn ignition key to RUN. 2. Clear learning memory using the scan tool. 3. Turn the ignition key to OFF/LOCKED for 2 seconds. 4. Turn the ignition key to RUN Clear DTCs. 5. Turn the ignition key to OFF/LOCKED for 2 seconds. 6. Turn ignition key to RUN. 7. After at least 7 seconds, read DTCs. 8. If DTCs resets See: Continuously Variable Transmission/Transaxle/Testing and Inspection Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 4112 Control Module: Removal and Replacement Removal REMOVAL 1. The TCM (2) is located between the brake pedal bracket (1) and the left kick panel (3). 2. Unplug the two electrical connectors (2) at the TCM. 3. Remove the two nuts (1) that hold the TCM to the bulkhead. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 4113 4. Remove the TCM. Installation INSTALLATION 1. Install TCM mounting bracket holes (1) over the two studs on the bulkhead. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Procedures > Page 4114 2. Install the two nuts to mounting studs (1) on the bulkhead and tighten to 15 Nm (130 in. lbs.). 3. Plug in electrical connectors (2) to TCM (3). NOTE: If a new TCM is installed a learn procedure must be performed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4119 Control Module: Diagrams Connector (AWD) - (BODY) 16 WAY MODULE-ALL WHEEL DRIVE CONTROL (AWD) - (BODY) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations > Page 4125 Fluid Pressure Sensor/Switch: Diagrams Connector - (BODY) 22 WAY ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH - (BODY) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Speed Sensor, CVT > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation DESCRIPTION The Vehicle Speed Sensor (VSS) is a hall effect sensor mounted above the transaxle differential. The sensor is triggered by the ring gear teeth passing below it. The VSS pulse signal to the speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Vehicle Speed Sensor - Removal Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor - Removal REMOVAL 1. Open hood. 2. Remove the air cleaner housing.See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal 3. Disconnect the speed sensor connector. CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal. 4. Remove speed sensor retaining bolt. 5. Remove speed sensor from transaxle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Vehicle Speed Sensor - Removal > Page 4138 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor - Installation INSTALLATION 1. Using a NEW O-ring, install the speed sensor to the transaxle. 2. Install the bolt and tighten to 7 Nm (60 in. lbs.). 3. Connect speed sensor connector. 4. Install the air cleaner housing.See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4144 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4145 Electronic Brake Control Module: Diagrams Connector - (ENGINE COMPARTMENT) 47 WAY MODULE-ANTI-LOCK BRAKES - (ENGINE COMPARTMENT) 47 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4146 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module - Description Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Description DESCRIPTION The Antilock Brake Module (ABM) is a microprocessor-based device which monitors the antilock brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop or when in a traction control or Electronic Stability Program (ESP) situation. The ABM utilizes a 47-way electrical connector on the vehicle wiring harness. The power source for the ABM is through the ignition switch in the RUN or ON position. The ABM (1) is mounted to the HCU (2) as part of the Integrated Control Unit (ICU). The ICU is located in the engine compartment on the inboard side of the right body frame rail behind the strut tower. For information on the ICU, See: Hydraulic Control Assembly - Antilock Brakes/Description and Operation/Integrated Control Unit (ICU) - Description - DESCRIPTION). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module - Description > Page 4149 Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Operation OPERATION The primary functions of the Antilock Brake Module (ABM) are to: - Monitor the Antilock Brake System (ABS) and Electronic Stability Program (ESP) for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in ABS or traction control mode. - Modulates fluid pressure to the wheel brakes to control vehicle yaw rate in ESP mode. - Store diagnostic information. - Provide communication to the scan tool while in diagnostic mode. - Illuminate the amber ABS indicator in the instrument cluster. - Illuminate the yellow ESP/BAS indicator in the instrument cluster (if equipped). The ABM constantly monitors the ABS and ESP (if equipped) for proper operation. If the ABM detects a fault, it will turn on the amber ABS and yellow ESP/BAS indicators and disable the ABS or ESP if so equipped. The normal base braking system will remain operational at that time. The ABM continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the ABM commands the ABM solenoid coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The ABM continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) Description Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control unit (HCU) - Description DESCRIPTION The Hydraulic Control Unit (HCU) is mounted to the Antilock Brake Module (ABM) as part of the Integrated Control Unit (ICU). The HCU controls the flow of brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on the HCU to empty the accumulators during an ABS stop and supply build pressure to the brakes during a traction control or ESP event. VALVES AND SOLENOIDS The valve block contains four inlet valves and four outlet solenoid valves. The inlet valves are spring-loaded in the open position and the outlet valves are spring-loaded in the closed position during normal braking. The fluid is allowed to flow from the master cylinder to the wheel brakes. During an ABS stop, these valves cycle to maintain the proper slip ratio for each wheel. The inlet valve closes preventing further pressure increase and the outlet valve opens to provide a path from the wheel brake to the HCU accumulators and pump/motor. This releases (decays) pressure from the wheel brake, thus releasing the wheel from excessive slippage. Once the wheel is no longer slipping, the outlet valve is closed and the inlet valve is opened to reapply (build) pressure. If the ABS includes the traction control feature, there are four other valves in the HCU. Two Traction Control (TC) (or ESP) valves, mounted in the HCU valve block, are normally in the open position and close only when the traction control is applied. There are also two normally closed shuttle valves which open during traction control and ESP events to provide a direct fluid path from the brake fluid reservoir to the inlet of the HCU pump. These TC valves are used to isolate the rear (non-driving) wheels of the vehicle from the hydraulic pressure that the HCU pump/motor is sending to the front (driving) wheels when traction control is being applied. The rear brakes need to be isolated from the master cylinder when traction control is being applied so the rear wheels do not drag. BRAKE FLUID ACCUMULATORS There are two fluid accumulators in the HCU: one for the primary hydraulic circuit, and one for the secondary hydraulic circuit. Each hydraulic circuit uses a 3 cc accumulator. The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during an ABS cycle. This stored fluid is used by the pump/motor to provide build pressure for the brake hydraulic system. When the antilock stop is complete, the accumulators are drained by the pump/motor. There are two noise dampening chambers in the HCU on this vehicle equipped with traction control. PUMP/MOTOR There are two pump assemblies in the HCU: one for the primary hydraulic circuit, and one for the secondary hydraulic circuit. Both pumps are driven by a common electric motor. This DC-type motor is integral to the HCU and is controlled by the ABM. Brake fluid is released to the accumulators when the outlet valve is opened during an antilock stop. The pump mechanism consists of two opposing pistons operated by an eccentric camshaft. In operation, these pistons are used to purge fluid from the accumulators back into the master cylinder circuits. When the antilock stop is complete, the pump/motor drains the accumulators. The pump motor is also used to build pressure when the system goes into Electronic Stability Program (ESP(R)) and traction control mode. The ABM may turn on the pump/motor when an antilock stop is detected. The pump/motor continues to run during the antilock stop and is turned off after the stop is complete. Under some conditions, the pump/motor runs to drain the accumulators during the next drive-off. The pump/motor is not a serviceable item; if it requires replacement, the HCU must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) Description > Page 4154 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Integrated Control Unit (ICU) - Description DESCRIPTION The Hydraulic Control Unit (HCU) (2) and the Antilock Brake Module (ABM) (1) used with this antilock brake system are combined (integrated) into one unit, which is called the Integrated Control Unit (ICU). The ICU (1) is located in the engine compartment, mounted to the right side body frame rail near the strut tower. Two different ICU's are used on this vehicle depending on whether or not the vehicle is equipped with traction control and Electronic Stability Program (ESP(R)). The HCU on a vehicle equipped with traction control or ESP(R) has a valve block that is approximately one inch longer than a HCU on a vehicle that is equipped with ABS only. The ABS-only ICU consists of the following components: the ABM, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), valve block, fluid accumulators, a pump, and an electric motor. The ABS with ESP(R) and All-Speed Traction Control ICU consists of the following components: the ABM, eight (build/decay) solenoid valves, two traction control solenoid valves, two shuttle valves, valve block, fluid accumulators, a pump, and an electric pump/motor. The replaceable components of the ICU are the HCU and the ABM. No attempt should be made to service any components of the HCU or ABM. For additional information on the ABM, See: Electronic Brake Control Module/Description and Operation/Anti-Lock Brake System Module - Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) Description > Page 4155 Description. For additional information on the HCU, See: Hydraulic Control unit (HCU) - Description - DESCRIPTION). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) Description > Page 4156 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Integrated Control Unit (ICU) - Operation OPERATION For information of the ICU, refer to these individual components of the ICU: - ANTILOCK BRAKE MODULE (ABM) See: Electronic Brake Control Module/Description and Operation/Anti-Lock Brake System Module - Description - HYDRAULIC CONTROL UNIT (HCU) See: Hydraulic Control unit (HCU) - Description DESCRIPTION) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement Hydraulic Control Assembly - Antilock Brakes: Removal and Replacement Hydraulic Control unit (HCU) - Installation INSTALLATION To install the HCU, assemble and install the ICU. See: Overhaul/Integrated Control Unit (ICU) Assembly See: Integrated Control Unit (ICU) - Installation Integrated Control Unit (ICU) - Removal GAS ENGINE NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Disconnect and isolate battery negative cable from battery post. 2. Using a brake pedal holding tool as shown, depress the brake pedal past its first 25 mm (1 inch) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir while the lines are disconnected. 3. Remove the engine appearance cover. 4. Loosen lower and upper mounting nuts, then remove the exhaust heat shield from the dash panel. 5. Pull the brake tube bundle routing clips (with tubes) loose from studs on the dash panel. 6. Remove the primary (4) and secondary (1) brake tubes (from master cylinder) at the hydraulic control unit (7). 7. Remove the remaining brake tubes (2, 3, 5, 6) at the hydraulic control unit (7). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4159 8. Remove the screw (1) fastening the power steering pressure hose routing clamp (2) to the exhaust manifold. NOTE: Use this figure in the following step to release the ABM harness connector cover. It shows the location of the release tabs. 9. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so: a. Depress the tabs on each side of the connector cover, then b. Pull outward and upward on the lower half of the cover until it locks into position pointing straight outward (2). The connector can then be Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4160 pulled straight outward off the ABM (1). 10. Loosen, but do not remove, the two mounting screws (2) attaching the ICU (1) mounting bracket to the body. 11. Lift the ICU and mounting bracket (1) off the mounting screws (2). 12. Move the brake tubes around as necessary without bending them and remove the ICU with bracket through the opening between the A/C lines and the exhaust manifold. 13. To separate the ABM from the HCU, See: Overhaul/Integrated Control Unit (ICU) Disassembly - DISASSEMBLY). Integrated Control Unit (ICU) - Installation GAS ENGINE 1. Install the ICU with bracket (1) through the opening between the A/C lines and the exhaust manifold using the opposite of how it was removed. 2. Place the mounting bracket for the ICU (1) over the mounting screws (2) and hang the assembly in place. Tighten the two mounting screws (2) to 23 Nm (17 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4161 CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector. 3. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place. 4. Install the four chassis brake tubes (2, 3, 5, 6) brake tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 Nm (150 in. lbs.). 5. Install the primary (4) and secondary (1) brake tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 Nm (150 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4162 6. Position the power steering pressure hose routing clamp (2) on the exhaust manifold and install the mounting screw (1). Tighten the mounting screw to 9 Nm (80 in. lbs.). 7. Push the brake tube bundle routing clips (with tubes) onto the studs on the dash panel. 8. Install the heat shield on the dash panel and tighten the lower and upper mounting nuts. 9. Remove the brake pedal holding tool. 10. Install the engine appearance cover. 11. Connect the battery negative cable to the battery post. It is important that this be performed properly. See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection 12. Hook up the scan tool to initialize the ABM and perform the following: a. Clear any faults. b. Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems. See: Brake Bleeding/Service and Repair c. Check for leaks. d. Perform the ABS Verification Test, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test and road test the vehicle. Hydraulic Control unit (HCU) - Removal REMOVAL To remove the HCU, the ICU must be removed and disassembled. See: Integrated Control Unit (ICU) - Removal See: Overhaul/Integrated Control Unit (ICU) - Disassembly Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4163 Hydraulic Control Assembly - Antilock Brakes: Overhaul Integrated Control Unit (ICU) - Assembly ASSEMBLY 1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant. 2. If the seals (1) on the solenoid valve stems (2) are not new, replace them all. Each of the solenoid valve stem seals must be new to keep out moisture and debris; do not reuse solenoid valve stem seals. 3. Replace the pump/motor connector O-ring (1) if it is not new. Be sure the O-ring is properly seated in the mounting groove (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4164 4. Align components and install the ABM (1) on the HCU (2). 5. If not equipped with ESP(R) or traction control, install the three screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2 Nm (17 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4165 6. If equipped with ESP(R) or traction control, install the four screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2 Nm (17 in. lbs.). 7. If necessary, install the mounting pins (1) in the ICU (2) and tighten to 11 Nm (97 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4166 8. If the mounting bracket (3) needs to be installed on the ICU (1), install the mounting pins in the ICU as necessary and tighten to 11 Nm (97 in. lbs.). Insert the mounting pins into the grommets mounted in the bracket, then install the single mounting bolt (2). Tighten the mounting bolt to 11 Nm (97 in. lbs.). 9. Install the ICU in the vehicle. See: Removal and Replacement/Integrated Control Unit (ICU) Installation Integrated Control Unit (ICU) - Disassembly DISASSEMBLY 1. If the mounting bracket (3) needs to be removed from the ICU, remove the single mounting bolt (2), then slide the ICU's mounting pins out of the grommets in the bracket and remove the bracket. 2. Remove the mounting pins from the ICU. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4167 3. If not equipped with ESP(R) or traction control, remove the three screws (1) attaching the ABM (2) to the HCU. 4. If equipped with ESP(R) or traction control, remove the four screws (1) attaching the ABM (2) to the HCU. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4168 5. Separate the ABM (1) from the HCU (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 4172 Lateral Accelerometer: Diagrams Connector (ESP) - (BODY) 6 WAY SENSOR-DYNAMICS (ESP) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations > Page 4173 Lateral Accelerometer: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (2). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal Lateral Accelerometer: Service and Repair Dynamics Sensor - Removal REMOVAL NOTE: The Occupancy Restraint Module (ORC) (4) is directly behind the vehicle dynamics sensor (2). Care must be taken while working near the ORC to avoid jostling or bumping the module. 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the shifter housing. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Housing - Removal 3. Position the carpeting out of the way so that the dynamics sensor is accessible. 4. Remove the two nuts (1) mounting the dynamics sensor to the floor pan tunnel. 5. Disconnect the wiring harness connector (3) at the dynamics sensor (2). 6. Remove the dynamics sensor (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 4176 Lateral Accelerometer: Service and Repair Dynamics Sensor - Installation INSTALLATION NOTE: The Occupancy Restraint Module (ORC) (4) is directly behind the vehicle dynamics sensor (2). Care must be taken while working near the ORC to avoid jostling or bumping the module. 1. Connect the wiring harness connector (3) to the dynamics sensor (2). 2. Install the dynamics sensor (2) over the studs mounted to the floor pan tunnel. 3. Install the two mounting nuts (1). Tighten the nuts to 9 Nm (80 in. lbs.). 4. Move carpeting back into original location. 5. Install the shifter housing See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Housing - Installation 6. Connect the battery negative cable to the battery post. It is important that this be performed properly See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection 7. Perform the Verification Test and clear any faults See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 4180 Steering Angle Sensor: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SENSOR-STEERING ANGLE - (INSTRUMENT PANEL) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Description and Operation Traction Control Switch: Description and Operation DESCRIPTION The ESP Off Switch is part of the accessory switch bank module located in the center bezel on the instrument panel above the transmission gear shifter. The ESP Off switch turns the Electronic Stability Program off whenever the switch is depressed. Depressing the switch a second time turns the ESP(R) back on. The switch resets itself each time the ignition is cycled. When the ESP Off switch is depressed and released, turning ESP(R) off, it does not completely turn the system off. The ESP(R) system reduces torque management to a lesser amount, but ESP(R) function can still occur if the system perceives the need. The ESP Off switch is serviced as part of the accessory switch bank. There are different accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Service and Repair > Electronic Stability Program (ESP) Switch - Removal Traction Control Switch: Service and Repair Electronic Stability Program (ESP) Switch - Removal REMOVAL NOTE: The ESP Off switch is integral to the accessory switch bank and cannot be serviced separately. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a work bench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the screws that secure the accessory switch bank to the back of the center bezel and remove the accessory switch bank. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Service and Repair > Electronic Stability Program (ESP) Switch - Removal > Page 4186 Traction Control Switch: Service and Repair Electronic Stability Program (ESP) Switch - Installation INSTALLATION NOTE: The ESP Off switch is serviced as part of the accessory switch bank. NOTE: There are different instrument panel accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. 1. Position the accessory switch bank onto the back of the instrument panel center bezel. 2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the center bezel onto the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Reconnect the negative battery cable. 5. Perform the ABS Verification Test and make sure the ESP Off switch operates properly. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test 6. Verify proper operation of all components controlled by the switch bank. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left Front ABS Wheel Speed Sensor Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left Front ABS Wheel Speed Sensor > Page 4191 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left Front ABS Wheel Speed Sensor > Page 4192 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left Front ABS Wheel Speed Sensor > Page 4193 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way Wheel Speed Sensor: Diagrams Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT FRONT - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 4196 Wheel Speed Sensor: Diagrams Left Front ABS Wheel Speed Sensor (Sensor Side) (Engine Compartment) 2 Way Connector (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT FRONT (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 4197 Wheel Speed Sensor: Diagrams Left Rear ABS Wheel Speed Sensor (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT REAR - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 4198 Wheel Speed Sensor: Diagrams Left Rear ABS Wheel Speed Sensor (Sensor Side) (Body) 2 Way Connector (SENSOR SIDE) - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT REAR (SENSOR SIDE) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 4199 Wheel Speed Sensor: Diagrams Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT FRONT - (ENGINE COMPARTMENT) 2 WAY Left Front ABS Wheel Speed Sensor (Sensor Side) (Engine Compartment) 2 Way Connector (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT FRONT (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 4200 Left Rear ABS Wheel Speed Sensor (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT REAR - (BODY) 2 WAY Left Rear ABS Wheel Speed Sensor (Sensor Side) (Body) 2 Way Connector (SENSOR SIDE) - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT REAR (SENSOR SIDE) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 4201 Right Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT FRONT - (ENGINE COMPARTMENT) 2 WAY Right Front ABS Wheel Speed Sensor (Sensor Side) (Engine Compartment) 2 Way Connector (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT FRONT (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 4202 Right Rear ABS Wheel Speed Sensor (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT REAR - (BODY) 2 WAY Right Rear ABS Wheel Speed Sensor (Sensor Side) (Body) 2 Way Connector (SENSOR SIDE) - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT REAR (SENSOR SIDE) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 4203 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description Wheel Speed Sensor: Description and Operation Wheel Speed Sensor - Description Front DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magneto-resistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. A front wheel speed sensor (3) is attached to a mounting boss on each front knuckle (4). The encoder is an integral part of the hub and bearing. WSS air gaps are not adjustable. Rear DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magnetoresistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. The rear wheel speed sensor head (3) is mounted to the rear of the hub and bearing by a screw. The encoder is integral to the hub and bearing assembly. The encoder is are serviced as part of the rear hub and bearing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description > Page 4206 The WSS air gaps are not adjustable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description > Page 4207 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor - Operation Front OPERATION The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Rear OPERATION The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Removal Front REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Open the hood. 2. Disconnect the wheel speed sensor cable connector (2) from the wiring harness connector (3) on top of the frame rail (1) to the inside of the strut tower. 3. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 4. Remove the grommet (1) from the hole in the body (7) and pull the wheel speed sensor cable out of the hole. 5. Remove the speed sensor cable routing clip (2) from the outside frame rail (6). 6. Remove the screw fastening the cable routing clamp (3) to the outside frame rail (6). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4210 7. Remove the screw (1) securing the wheel speed sensor routing bracket (2) to the brake flex hose bracket (5). 8. Remove the mounting screw (2) fastening the wheel speed sensor head (3) to the knuckle (4). Pull the sensor head out of the knuckle. NOTE: In the following step, the routing clip can be easily removed without damaging it by rotating it (with entire sensor) counterclockwise. 9. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (4). Remove the sensor from the vehicle. Rear REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4211 NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Remove the cargo floor cover. 2. Remove the rear floor pan silencer (1). 3. If equipped, remove the nuts mounting the satellite receiver (1) or amplifier (2) to rear floor pan. Move the component aside to allow access to the wheel speed sensor wiring connector through the opening in bottom of the quarter trim panel. 4. Through the opening in the bottom of the quarter trim panel, disconnect the wheel speed sensor cable connector (2) at the body wiring harness connector (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4212 5. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair. 6. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly (1). 7. Remove the grommet (2) from the hole in the body (1) and pull the wheel speed sensor cable out through the hole. 8. Remove the speed sensor cable routing clip (3) from the outside frame rail (4). 9. Remove the screw (1) fastening the cable routing clamp (3) to the rear suspension crossmember (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4213 10. Remove the speed sensor cable routing clip (1) from the trailing link (2). 11. Remove the screw (4) fastening the cable routing clamp to the trailing link. 12. Remove the screw (1) fastening the wheel speed sensor head (3) in the rear of the hub and bearing (2). Remove the sensor from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4214 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Installation Front INSTALLATION CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. 1. Install the wheel speed sensor head (3) into the knuckle (4). Install the mounting screw (2) and tighten it to 12 Nm (106 in. lbs.). 2. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (4). 3. Position the wheel speed sensor routing bracket (2) on the brake flex hose bracket (5) and install the mounting screw (1). Tighten the mounting screw to 18 Nm (13 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4215 4. Position the wheel speed sensor cable routing clamp (4) on the outside frame rail (6) and install the mounting screw (3). Tighten the mounting screw to 18 Nm (13 ft. lbs.). 5. Install the speed sensor cable routing clip (2) on the outside frame rail (6). 6. Insert the wheel speed sensor cable through the hole in the body (7) and install the grommet (1) in the hole. 7. Lower the vehicle. 8. Connect the wheel speed sensor cable connector (2) to the wiring harness connector (3) on top of the frame rail (1). 9. Perform the Diagnostic Verification Test and clear any faults. See: Brake Bleeding/Service and Repair Rear INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4216 1. Install the wheel speed sensor head (3) into the rear of the hub and bearing (2). 2. Install the wheel speed sensor head mounting screw (1). Tighten the screw to 10 Nm (89 in. lbs.). 3. Position the wheel speed sensor (3) on the trailing link (2) and install the screw (4) securing it in place. Tighten the mounting screw to 18 Nm (13 ft. lbs.). 4. Position the wheel speed sensor (3) and install the routing clip (1) fastening the sensor to the trailing link (2). 5. Position the wheel speed sensor cable routing clamp (3) on the rear suspension crossmember (4) and install the mounting screw (1). Tighten the mounting screw to 18 Nm (13 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4217 6. Install the speed sensor cable routing clip (3) on the outside frame rail (4). NOTE: When inserting the wheel speed sensor cable through the hole in the body, route the cable toward the shock tower to make it easier to grasp the cable to connect it to the body wiring harness connector in a later step. 7. Insert the wheel speed sensor cable (5) through the hole in the body (1) and install the grommet (2) in the hole. 8. Install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4218 10. Through the opening in the bottom of the quarter trim panel, connect the wheel speed sensor cable connector (2) at the body wiring harness connector (3). 11. If equipped, install the satellite receiver (1) or amplifier (2) to rear floor pan. 12. Install the rear floor pan silencer (1). 13. Install the cargo floor cover. 14. Perform the Diagnostic Verification Test and clear any faults. See: Brake Bleeding/Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 4222 Yaw Rate Sensor: Diagrams Connector (ESP) - (BODY) 6 WAY SENSOR-DYNAMICS (ESP) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations > Page 4223 Yaw Rate Sensor: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (2). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal Yaw Rate Sensor: Service and Repair Dynamics Sensor - Removal REMOVAL NOTE: The Occupancy Restraint Module (ORC) (4) is directly behind the vehicle dynamics sensor (2). Care must be taken while working near the ORC to avoid jostling or bumping the module. 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the shifter housing. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Housing - Removal 3. Position the carpeting out of the way so that the dynamics sensor is accessible. 4. Remove the two nuts (1) mounting the dynamics sensor to the floor pan tunnel. 5. Disconnect the wiring harness connector (3) at the dynamics sensor (2). 6. Remove the dynamics sensor (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 4226 Yaw Rate Sensor: Service and Repair Dynamics Sensor - Installation INSTALLATION NOTE: The Occupancy Restraint Module (ORC) (4) is directly behind the vehicle dynamics sensor (2). Care must be taken while working near the ORC to avoid jostling or bumping the module. 1. Connect the wiring harness connector (3) to the dynamics sensor (2). 2. Install the dynamics sensor (2) over the studs mounted to the floor pan tunnel. 3. Install the two mounting nuts (1). Tighten the nuts to 9 Nm (80 in. lbs.). 4. Move carpeting back into original location. 5. Install the shifter housing See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Housing - Installation 6. Connect the battery negative cable to the battery post. It is important that this be performed properly See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection 7. Perform the Verification Test and clear any faults See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding Brake Bleeding: Service and Repair Base Brake Bleeding BASE BRAKE BLEEDING NOTE: For bleeding the ABS hydraulic system, refer to Antilock Brake System Bleeding in the Antilock Brake System section. See: Antilock Brake System Bleeding CAUTION: Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder reservoir. CAUTION: Use only Mopar(R) brake fluid or an equivalent from a fresh, tightly sealed container. Brake fluid must conform to DOT 3 specifications. NOTE: For bleeding of the Antilock Brake System, See: . Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process. This will only increase the amount of air in the system and make additional bleeding necessary. Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air into the brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. - Left rear wheel - Right front wheel - Right rear wheel - Left front wheel MANUAL BLEEDING NOTE: To bleed the brakes manually, the aid of a helper will be required. 1. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With the pedal in the down position, open the bleeder screw at least one full turn. 4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 4231 6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir (2) to make sure it does not go dry. 7. Check and adjust brake fluid level to the FULL mark. 8. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. 9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. PRESSURE BLEEDING NOTE: Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. 1. Attach Master Cylinder Cap 6921 (2) in place of the filler cap on the master cylinder reservoir (3). 2. Attach Bleeder Tank C-3496-B (1) or an equivalent, to the Master Cylinder Cap 6921 (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 4232 3. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 4. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 5. After approximately 120-240 ml (4-8 ounces) of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 6. Repeat this procedure at all the remaining bleeder screws. 7. Check and adjust brake fluid level to the FULL mark on the reservoir (2). 8. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. 9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 4233 Brake Bleeding: Service and Repair Antilock Brake System Bleeding ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Brake systems with ABS must be bled as two independent braking systems. The non-ABS portion of the brake system with ABS is to be bled the same as any non-ABS system. The ABS portion of the brake system must be bled separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. NOTE: During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add Mopar(R) DOT 3 brake fluid as required. BLEEDING When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the scan tool to the diagnostics connector. The diagnostic connector is located under the lower steering column cover to the left of the steering column. 3. Using the scan tool, check to make sure the ABM does not have any fault codes stored. If it does, clear them. WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube (1) must be attached to the bleeder screws and submerged in a clear container filled part way with clean brake fluid (2). Direct the flow of brake fluid away from yourself and the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the bleeder screws when opened. NOTE: Pressure bleeding is recommended to bleed the base brake system to ensure all air is removed from system. Manual bleeding may also be used, but additional time is needed to remove all air from system. 4. Bleed the base brake system. See: 5. Using the scan tool, select ECU VIEW, followed by ABS MISCELLANEOUS FUNCTIONS to access bleeding. Follow the instructions displayed. When finished, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 4234 7. Fill the master cylinder fluid reservoir (1) to the FULL level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake and/or Accelerator Pedals - Removal Brake Pedal Assy: Service and Repair Brake and/or Accelerator Pedals - Removal LEFT-HAND DRIVE NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Disconnect and isolate the battery negative cable from its post on the battery. 2. If equipped, remove the silencer pad below the steering column opening cover. 3. Remove the steering column opening cover on the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal 4. Remove the reinforcement behind the steering column opening cover. 5. Remove the stop lamp switch See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Removal 6. Remove the retaining clip (2) securing the power brake booster push rod (1) to the brake pedal. To do so, position a small screwdriver under the center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin (3). Remove and discard the clip. Do not reuse the clip. 7. Slide the booster push rod (1) off the brake pedal pin (3). 8. Remove the four nuts (4) attaching the brake pedal (1) (and power brake booster) to the dash panel. 9. Remove the remaining nut (5) attaching the brake pedal (1) to the dash panel. 10. Remove the brake pedal (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake and/or Accelerator Pedals - Removal > Page 4239 Brake Pedal Assy: Service and Repair Brake and/or Accelerator Pedals - Installation LEFT-HAND DRIVE 1. Carefully install the brake pedal and bracket assembly (1) in the vehicle lining up the bracket with the power brake booster mounting studs and the stud (2) on the dash panel. 2. Install the four nuts (4) attaching the brake pedal (1) (and power brake booster) to the dash panel. Do not tighten the nuts at this time. 3. Install the remaining nut (5) attaching the brake pedal (1) to the dash panel. To tighten this nut (and the other four from the preceding step), refer to the following step. CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence. 4. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 Nm (17 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake and/or Accelerator Pedals - Removal > Page 4240 5. Using Mopar(R) Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster push rod (1). 6. Install the power brake booster push rod (1) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of the pin. Do not reuse the old clip. 7. Install and adjust the stop lamp switch in the brake pedal bracket See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Installation 8. Install the steering column opening cover reinforcement in the steering column opening. 9. Install the steering column opening cover (and airbag if equipped) on the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover Installation 10. If equipped, install the silencer pad below the instrument panel. 11. Connect the battery negative cable to its post on the battery. 12. Check the stop lamps to verify they are operating properly and not staying on when the pedal is in the released position. 13. Road test the vehicle to ensure proper operation of the brakes. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures Brake Caliper: Procedures Front CLEANING WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R) Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. Rear CLEANING WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R) Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. Front INSPECTION Inspect the disc brake caliper for the following: - Brake fluid leaks in and around piston boot area - Ruptures, brittleness or damage to the piston dust boot If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Rear INSPECTION Inspect the disc brake caliper for the following: - Brake fluid leaks in and around boot area and inboard lining - Ruptures, brittleness or damage to the piston dust boot - Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4246 Brake Caliper: Removal and Replacement Front REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch (25 mm) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir when the lines are opened. 2. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 3. Remove the wheel mounting nuts (3), then the tire and wheel assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4247 4. Remove the banjo bolt (4) connecting the brake flex hose (2) to the brake caliper (5). There are two washers (3) that will come off with the banjo bolt. Discard the washers. NOTE: When removing the caliper guide pin bolts (2, 3) note that one (upper) has a special sleeve on the end. It is important that this bolt be installed in the upper mounting hole when the caliper is installed. 5. Remove the two brake caliper guide pin bolts (2, 3). 6. Slide the disc brake caliper (4) from the disc brake adapter bracket (1) and brake pads and remove. Rear REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4248 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir while the lines are disconnected. 2. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 3. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. 4. Unthread the brake tube nut (2) at the rear flex hose. 5. Remove the clip (3) securing the rear flex hose to the trailing link mounted bracket. Remove the flex hose from the bracket. 6. Unthread and remove the brake flex hose (4) from the brake caliper (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4249 NOTE: When removing the caliper guide pin bolts (2, 3), note that one bolt has a special sleeve on the tip and the other does not. Depending on the build date (vehicle built before or after 7/27/06), this special sleeve bolt (3) can be located in either the top or bottom location. When installing, make sure the bolts are put back in the same locations as when removed to avoid NVH issues. 7. Remove the two brake caliper guide pin bolts (2, 3). 8. Slide and remove the disc brake caliper (1) with outboard brake pad attached from the disc brake adapter bracket, inboard brake pad and rotor. 9. Remove the outboard brake pad from the caliper by prying the brake pad retaining clip over the raised area on the caliper. Slide the brake pad off of the brake caliper. Front INSTALLATION 1. Completely retract the caliper piston back into the bore of the caliper. Use a C-clamp to retract the piston. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston. CAUTION: Use care when installing the caliper (4) onto the adapter bracket (1) to avoid damaging the guide pin boots. 2. Install the disc brake caliper over the brake pads on the brake caliper adapter bracket. NOTE: When installing the caliper guide pin bolts (2, 3) make sure that the one that has a special sleeve on the end is installed in the upper mounting hole. 3. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper (with special sleeve) (2) and lower (3) caliper guide pin bolts. Tighten the guide pin bolts to 43 Nm (32 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4250 4. Install the banjo bolt (4) connecting the brake flex hose (2) to the brake caliper (5). Install NEW washers (3) on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to 24 Nm (18 ft. lbs.). 5. Install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Remove the brake pedal holding tool. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4251 8. Bleed the caliper as necessary. See: Brake Bleeding/Service and Repair 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. Rear INSTALLATION 1. If not already performed, completely retract the caliper piston back into the piston bore of the caliper. Use a C-clamp to retract the piston. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston. 2. Slide the outboard brake pad onto the caliper. Be sure the retaining clip is squarely seated in the depressed areas on the caliper beyond the raised retaining bead. CAUTION: Use care when installing the caliper onto the disc brake adapter to avoid damaging the guide pin boots. 3. Install the disc brake caliper with outboard brake pad attached over the inboard brake pad and rotor, onto the brake caliper adapter bracket. NOTE: When installing the caliper guide pin bolts (2, 3), make sure the bolts are put back in the same locations as when removed to avoid NVH issues. Depending on the build date (vehicles built before or after 7/27/06) and services performed, the location of the bolt with the special sleeve on the tip (3) can vary. 4. Align the caliper guide pin bolt holes with the adapter bracket. Install the lower (2) and upper (with special sleeve) (3) caliper guide pin bolts. Tighten the guide pin bolts to 43 Nm (32 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4252 5. Thread the rear brake flex hose (4) into the brake caliper (1). Tighten the flex hose fitting at the caliper to 15 Nm (133 in. lbs.). 6. Route and install the brake flex hose into the trailing link mounted bracket. Install the clip (3) securing the flex hose to the bracket. 7. Thread the brake tube nut (2) into brake flex hose. Tighten the brake tube nut to 17 Nm (150 in. lbs.). 8. Install tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. 10. Remove the brake pedal holding tool. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4253 11. Bleed the caliper as necessary. See: Brake Bleeding/Service and Repair 12. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4254 Brake Caliper: Overhaul Rear DISASSEMBLY NOTE: Before disassembling the brake caliper, remove it from the vehicle. See: Removal and Replacement/Disc Brake Caliper - Removal NOTE: Before disassembling the brake caliper, clean and inspect it. See: Procedures/Disc Brake Caliper - Cleaning See: Procedures/Disc Brake Caliper - Inspection 1. With finger tip, trace around the outside perimeter of the piston dust boot to find the ends of the boot snap-ring. 2. Using a small screwdriver (2) or like tool, carefully remove the boot snap-ring (1) making sure not to damage the dust boot, piston or piston bore. 3. Carefully pull the piston dust boot away from the caliper boot groove. WARNING: Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 4. Mount the caliper in a vise equipped with protective jaws. WARNING: Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure. 5. Place a wooden block (2) in the caliper as shown. 6. As necessary, apply low pressure compressed air to the caliper fluid inlet in short spurts to force the piston (1) out. 7. Remove the piston (with dust boot) from the caliper. 8. Remove the dust boot from the piston and discard it. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4255 CAUTION: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. 9. Using a soft tool such as a plastic trim stick (2), work the piston seal (1) out of its groove (3) in the caliper piston bore. Discard the used seal. 10. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 11. Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Front DISASSEMBLY NOTE: Before disassembling the brake caliper, remove it from the vehicle. See: Removal and Replacement/Disc Brake Caliper - Removal NOTE: Before disassembling the brake caliper, clean and inspect it. See: Procedures/Disc Brake Caliper - Cleaning See: Procedures/Disc Brake Caliper - Inspection WARNING: Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 1. Mount the caliper in a vise equipped with protective jaws. WARNING: Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure. 2. Place a wooden block (1) in the caliper as shown. 3. If necessary, apply low pressure compressed air to the caliper fluid inlet in short spurts to force the piston out. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4256 4. Remove the piston from the caliper. 5. Remove the dust boot from the piston and discard it. CAUTION: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. 6. Using a soft tool such as a plastic trim stick (1), work the piston seal (2) out of its groove in caliper piston bore. Discard the used seal. 7. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Rear ASSEMBLY NOTE: Always have clean hands when assembling a brake caliper. NOTE: Always use fresh, clean brake fluid when assembling a brake caliper. NOTE: Never use an old piston seal. 1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper piston bore. The seal (1) should be started at one area of the groove and gently worked around into the groove using only clean finger tips to seat it. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4257 2. Coat the NEW piston dust boot (1) with clean brake fluid leaving a generous amount inside the boot. 3. Position the dust boot over the top of the piston (2) and into the piston groove. Make sure the side of the dust boot with the outer lip (3) for the boot snap-ring is positioned upward as shown. 4. Coat the piston with clean brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. 5. Insert the piston into the caliper bore, carefully pushing it past the piston seal using hand pressure. Push the piston in until it bottoms in the caliper bore. 6. With finger tips, seat the dust boot lip (1) into the boot groove in the caliper bore. Trace around the outside perimeter of the dust boot with a finger tip making sure the lip is properly seated in the groove and not much air is trapped behind the boot. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4258 7. Position one end of the boot snap-ring (1) inside the boot outer lip (2), then making a circular motion, walk the snap-ring around the boot lip, completely installing and seating it. 8. Inspect whether the two ends of the boot snap-ring are not overlapping one another. If they are, push the snap ring and dust boot further into groove removing any overlap of the snap-ring. 9. Install the caliper on the vehicle and bleed the brakes as necessary. See: Removal and Replacement/Disc Brake Caliper - Installation Front ASSEMBLY NOTE: Always have clean hands when assembling a brake caliper. NOTE: Always use fresh, clean brake fluid when assembling a brake caliper. NOTE: Never use an old piston seal. 1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper bore. The seal (1) should be started at one area of the groove and gently worked around into the groove using only your clean fingers to seat it. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4259 2. Coat the NEW piston with clean brake fluid. 3. Coat the NEW piston boot with clean brake fluid leaving a generous amount inside the boot. 4. Position the dust boot over the lower section of the piston. 5. Extend the dust boot below the bottom of the piston and guide the lip seal into the groove in the caliper piston bore. CAUTION: Force applied to the piston (1) to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. 6. Install the piston (1) into the bore, carefully pushing it past the piston seal using hand pressure. Push the piston in until it bottoms in the caliper bore and the dust boot lip seal falls into the groove near the top of the piston. 7. Install the caliper on the vehicle and bleed the brakes as necessary. See: Removal and Replacement/Disc Brake Caliper - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications BRAKE PAD Measure brake pad minimum thickness (1). Brake pads must be replaced when usable material on a brake pad lining (2) measured at its thinnest point measures one millimeter (0.04 inches) or less. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures Brake Pad: Procedures Front CLEANING WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. Rear CLEANING WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. Front INSPECTION Visually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators (if equipped) on the pads and the brake rotors. If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake pads from the vehicle. Measure brake pad minimum thickness (1). Brake pads must be replaced when usable material on a brake pad lining (2) measured at its thinnest point measures one millimeter (0.04 inches) or less. If a brake pad fails inspection, replace both disc brake pads (inboard and outboard) at each caliper. It is also necessary to replace the pads on the opposite side of the vehicle as well as the pads failing inspection to maintain proper braking characteristics. If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the original position they were removed from. NOTE: It is important to inspect both front and rear brake pads during the same inspection. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 4265 Rear INSPECTION Visually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators (if equipped) on the pads and the brake rotors. If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake pads from the vehicle. Measure brake pad minimum thickness (1). Brake pads must be replaced when usable material on a brake pad lining (2) measured at its thinnest point measures one millimeter (0.04 inches) or less. If a brake pad fails inspection, replace both disc brake pads (inboard and outboard) at each caliper. It is also necessary to replace the pads on the opposite side of the vehicle as well as the pads failing inspection to maintain proper braking characteristics. If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the original position they were removed from. NOTE: It is important to inspect both front and rear brake pads during the same inspection. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 4266 Brake Pad: Removal and Replacement Front REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair NOTE: Perform 2 through 5 on each side of the vehicle to complete pad set removal. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). NOTE: When removing the caliper guide pin bolts (2, 3) note that one (upper) has a special sleeve on the end. It is important that this bolt be installed in the upper mounting hole when the caliper is installed. 3. Remove the two brake caliper guide pin bolts (2, 3). 4. Remove the disc brake caliper (4) from the disc brake adapter bracket (1) and hang it out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 4267 5. Remove the brake pads (4, 5) from the caliper adapter bracket (2). Rear REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . NOTE: If the rear brake pads are being replaced due to a howl or moan while driving in reverse, proper diagnosis and correction is essential. See: Testing and Inspection/Component Tests and General Diagnostics 1. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair NOTE: Perform 2 through 6 on each side of the vehicle to complete pad set removal. 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the pads and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before the guide pin bolts are removed, by grasping the rear of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 4268 3. Remove the disc brake caliper (2) lower guide pin bolt (1). CAUTION: When moving rear brake caliper upward, use extreme care not to damage or overextend the flex hose. Damage may occur. 4. Rotate the caliper (1) upward hinging off the upper guide pin bolt. Rotate the caliper upward just enough to allow brake pad removal. Hang the caliper assembly in this position using wire or a bungee cord. 5. Remove the inboard brake pad (5) from the caliper adapter bracket (3). 6. Remove the outboard brake pad (2) from the caliper (1) by prying the brake pad retaining clip over the raised area on the caliper. Slide the brake pad off of the brake caliper. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 4269 Front INSTALLATION NOTE: Perform 1 through 5 on each side of the vehicle to complete pad set installation, then proceed to 6. NOTE: Make sure that the audible wear indicators (if equipped) are placed toward the top when the inboard brake pads are installed on each side of the vehicle. 1. Place the brake pads (4, 5) in the abutment shims (3) clipped into the disc brake caliper adapter bracket (2) as shown. Place the pad with the wear indicator attached on the inboard side (2). 2. Completely retract the caliper piston back into the bore of the caliper. CAUTION: Use care when installing the caliper (4) onto the adapter bracket (1) to avoid damaging the boots. 3. Install the disc brake caliper over the brake pads on the brake caliper adapter bracket. NOTE: When installing the caliper guide pin bolts (2, 3) make sure that the one that has a special sleeve on the end is installed in the upper mounting hole. 4. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper (with special sleeve) (2) and lower (3) caliper guide pin bolts. Tighten the guide pin bolts to 43 Nm (32 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 4270 5. Install tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Pump the brake pedal several times before moving the vehicle to set the pads to the brake rotor. 8. Check and adjust the brake fluid level in the reservoir (2) as necessary. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Rear INSTALLATION NOTE: If the rear pads are being replaced due to a howl or moan while driving in reverse, proper diagnosis and correction is essential. See: Testing and Inspection/Component Tests and General Diagnostics NOTE: Perform 1 through 6 on each side of the vehicle to complete pad set installation, then proceed to 7. 1. Completely retract the caliper piston back into the piston bore of the caliper. This is required to gain the necessary pad-to-rotor clearance for the caliper installation onto the steering knuckle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 4271 NOTE: Place the brake pad with the audible wear indicator attached on the inboard side. The audible wear indicator should be positioned at the bottom when installed. 2. Slide the outboard brake pad (2) onto the caliper (1). Be sure the retaining clip is squarely seated in the depressed areas on the caliper beyond the raised retaining bead. 3. Place the inboard brake pad (5) in the abutment shims (4) clipped into the disc brake caliper adapter bracket (3) as shown (see preceding note). CAUTION: Use care when installing the caliper onto the adapter bracket to avoid damaging the guide pin boot. 4. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 5. Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 43 Nm (32 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 4272 NOTE: Once the caliper is installed, inspect the outboard brake pad to make sure it is correctly positioned. The retaining clip (2) must be squarely seated in the depressed areas (1) on the caliper fingers. Also, the nubs on the pad's steel backing plate must be fully seated in the depressions formed into the inside of the caliper fingers. There should be no gap between the pad backing plate and the caliper fingers. 6. Install tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 7. Lower the vehicle. 8. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving the vehicle. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake pads. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications BRAKE ROTOR LIMITS/SPECIFICATIONS NOTE: When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits MUST BE MAINTAINED. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4276 Brake Rotor/Disc: Testing and Inspection BRAKE ROTOR Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This increases guide pin sleeve wear due to the tendency of the caliper to follow the rotor wobble. When diagnosing a brake noise or pulsation, the machined disc braking surface should be inspected. BRAKING SURFACE INSPECTION Light braking surface scoring and wear is acceptable. If heavy scoring or warping is evident, the rotor must be refaced or replaced. See: Service and Repair/Procedures. Excessive wear and scoring of the rotor can cause improper lining contact on the rotor's braking surface. If the ridges on the rotor are not removed before new brake shoes are installed, improper wear of the shoes will result. If a vehicle has not been driven for a period of time, the rotor's braking surface will rust in the areas not covered by the brake shoes at that time. Once the vehicle is driven, noise and chatter from the disc brakes can result when the brakes are applied. Some discoloration or wear of the rotor surface is normal and does not require resurfacing when linings are replaced. If cracks or burned spots are evident, the rotor must be replaced. ROTOR MINIMUM THICKNESS Measure rotor thickness (1) at the center of the brake pad contact surface. Replace the rotor if it is worn below minimum thickness or if machining the rotor will cause its thickness to fall below specifications. CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4277 On front rotors, Minimum thickness specifications (2) are cast on the rotor's unmachined surface on the inside of the rotor (1). Limits can also be found in this component's specification table. See: Specifications On rear rotors, Minimum thickness specifications (3) are cast into the rotor's unmachined surface on the outside of the rotor (1). This area also shows the maximum thickness specifications (2) for the hat section of the rotor. Limits can also be found in this component's specification table. See: Specifications ROTOR THICKNESS VARIATION Thickness variation in a rotor's braking surface can result in pedal pulsation, chatter and surge. This can also be caused by excessive runout in the rotor or the hub. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4278 Rotor thickness variation measurements should be made in conjunction with measuring runout. Measure thickness of the brake rotor (2) at 12 equal points around the rotor braking surface with a micrometer (1) at a radius approximately 25 mm (1 inch) from edge of rotor. If thickness measurements vary beyond the specification listed in the specification table See: Specifications , the rotor should be refaced or replaced. See: Service and Repair/Procedures. ROTOR RUNOUT On-vehicle rotor runout is the combination of the individual runout of the hub face and the runout of the brake rotor (hub runout can be measured separately). To measure rotor runout on the vehicle: 1. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 2. Remove the tire and wheel assembly. See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Removal 3. Install standard wheel mounting nuts, flat side to rotor, on all the wheel studs (2). Progressively tighten the nuts in a crisscross pattern to 135 Nm (100 ft. lbs.). 4. Mount Dial Indicator C-3339A (1) with Wheel 25w, or equivalent, to the knuckle. Position the dial indicator wheel to contact the rotor braking surface approximately 10 mm (0.39 in.) from the outer edge of the rotor (3). 5. Slowly rotate the brake rotor checking lateral runout, marking the low and high spots. Record these measurements. 6. Check and record the runout on the opposite side of the rotor in the same fashion, marking the low and high spots. 7. Compare runout measurement to specifications.See: Specifications 8. If runout is in excess of specifications, check the lateral runout of the hub face. Before removing the rotor from the hub, place a chalk mark across both the rotor (1) and the one wheel stud (2) closest to where the high runout measurement was taken. This way, the original mounting spot of the rotor on the hub is indexed. 9. Remove the rotor from the hub. See: Service and Repair/Removal and Replacement/Brake Rotor - Removal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4279 NOTE: Before measuring hub runout, clean the hub face surface with an appropriate cleaner. This provides a clean surface to get an accurate indicator reading. 10. Mount Dial Indicator C-3339A (2) to the knuckle. Position the dial indicator stem so it contacts the hub face (1) near the outer diameter. Care must be taken to position the stem outside of the stud circle, but inside of the chamfer on the hub rim. 11. Slowly rotate the hub measuring runout. Hub runout should not exceed 0.08 mm (0.003 inch). If runout exceeds this specification, the hub must be replaced. See: Steering and Suspension/Steering/Front Steering Knuckle/Service and Repair/Front Steering Knuckle - Removal See: Maintenance/Wheels and Tires/Wheel Bearing/Service and Repair/Rear Hub and Bearing - Removal 12. If hub runout does not exceed this specification, install the original rotor back on the hub, aligning the chalk mark on the rotor (2) with a wheel mounting stud, two studs apart from the original stud (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4280 13. Install standard wheel mounting nuts, flat side to rotor, on all the wheel studs (2). Progressively tighten the nuts in a crisscross pattern to 135 Nm (100 ft. lbs.). 14. Mount the Dial Indicator C-3339A (1) and remeasure runout on both sides of the brake rotor as explained in earlier steps to see if runout is now within specifications. See: Specifications 15. If runout is still not within specifications, reface or replace brake rotor. See: Service and Repair/Procedures Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures Brake Rotor/Disc: Procedures BRAKE ROTOR MACHINING NOTE: Refacing the rotor is not required each time the brake pads are replaced, only when the need is foreseen. Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. If the rotor surface is deeply scored or warped, or there is a complaint of brake roughness or brake pedal pulsation, the rotor should be refaced using a hub-mounted on-car brake lathe (1), or replaced. The use of a hub-mounted on-car brake lathe (1) is highly recommended to eliminate the possibility of excessive runout. It trues the brake rotor to the vehicle's hub and bearing. NOTE: All brake rotors (1) have markings for minimum allowable thickness cast on an unmachined surface of the rotor (2) or stamped into the hat section. On this vehicle, the minimum thickness specification for the front brake rotor is located on the inside of the rotor. The minimum thickness specification for the rear brake rotor is located on the outside of the rotor. Minimum thickness specifications can also be found in this component's specification table. See: Specifications Minimum allowable thickness is the minimum thickness which the brake rotor machined surface may be cut to. CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness. Before lathe installation, verify the brake rotor face and the hub adapters are free of any chips, rust, or contamination. When mounting and using the brake lathe, strict attention to the brake lathe manufacturer's operating instructions is required. Machine both sides of the brake rotor at the same time. Cutting both sides at the same time minimizes the possibility of a tapered or uneven cut. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4283 When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning equipment is required. Specifications for brake rotor machining can be founds specification table. See: Specifications Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4284 Brake Rotor/Disc: Removal and Replacement Front FRONT BRAKE ROTOR NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the pads and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before the guide pin bolts are removed, by grasping the inboard side of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. 3. Remove the two bolts (3) securing disc brake caliper and adapter bracket (1) to the steering knuckle (2). 4. Remove the disc brake caliper and adapter bracket (1) from the knuckle (2) and rotor (4) as an assembly. Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4285 5. Remove any clips (3) retaining the brake rotor (2) to the wheel studs. 6. Slide the brake rotor (2) off the hub and bearing (1). Rear REAR BRAKE ROTOR NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly. NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount in order to provide sufficient clearance between the pads and the rotor to easily remove the caliper from the knuckle. This can usually be accomplished before the guide pin bolts are removed, by grasping the inboard side of the caliper and pulling outward working with the guide pins, thus retracting the piston. Never push on the piston directly as it may get damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4286 3. Remove the disc brake caliper (2) lower guide pin bolt (1). CAUTION: When moving rear brake caliper upward, use extreme care not to damage or overextend the flex hose. Damage may occur. 4. Rotate the caliper upward hinging off the upper guide pin bolt. Rotate the caliper upward just enough to allow brake rotor removal. Hang the caliper assembly in this position using wire or a bungee cord. 5. Remove any clips (2) retaining the brake rotor (3) to the wheel studs. 6. Slide the brake rotor (3) off the hub and bearing (1) and remove. Front Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4287 FRONT BRAKE ROTOR NOTE: Inspect disc brake pads before installation. See: Brake Pad/Service and Repair/Procedures/Brake Pads - Inspection 1. Clean the hub face (1) to remove any dirt or corrosion where the rotor mounts. 2. Install the brake rotor (2) over the studs on the hub and bearing. 3. Install the disc brake caliper and adapter bracket assembly (1) over the brake rotor (4) and knuckle (2). 4. Install the mounting bolts (3) securing the caliper adapter bracket to the knuckle (2). Tighten the bolts to 108 Nm (80 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4288 5. Install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Pump the brake pedal several times before moving the vehicle to set the pads to the brake rotor. 8. Check and adjust the brake fluid level in the reservoir as necessary. 9. Road test the vehicle and make several stops to seat the brake pads to the rotor. Rear REAR BRAKE ROTOR NOTE: Inspect disc brake pads and parking brake shoes before installation. See: Brake Pad/Service and Repair/Procedures/Brake Pads Inspection 1. Clean the hub face (1) to remove any dirt or corrosion where the rotor mounts. 2. Install the brake rotor (3) over the studs on the hub and bearing (1). CAUTION: Use care when installing the caliper onto the adapter bracket to avoid damaging the guide pin boot. 3. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 4. Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 43 Nm (32 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4289 NOTE: Once the caliper is installed, inspect the outboard brake pad to make sure it is correctly positioned. The retaining clip (2) must be squarely seated in the depressed areas (1) on the caliper fingers. Also, the nubs on the pad's steel backing plate must be fully seated in the depressions formed into the inside of the caliper fingers. There should be no gap between the pad backing plate and the caliper fingers. 5. Install tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Pump the brake pedal several times before moving the vehicle to set the pads to the brake rotor. 8. Check and adjust the brake fluid level in the reservoir as necessary. 9. Road test the vehicle and make several stops to seat the brake pads to the rotor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Brake Backing Plate - Removal Backing Plate: Service and Repair Brake Backing Plate - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir. 2. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 3. Remove the wheel mounting nuts (3), then the tire and wheel assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Brake Backing Plate - Removal > Page 4295 4. Access and remove the drum brake shoes (6) from the support plate (2). See: Brake Shoe/Service and Repair/Removal and Replacement/Removal 5. Position a 10 mm box wrench (2) over the retainer fingers on the end of the parking brake cable housing (1). Compress the cable housing retaining fingers with the wrench, then pull the cable housing out of the support plate. 6. Disconnect the brake tube (2) at the wheel cylinder. 7. Remove the wheel cylinder attaching screws (1). 8. Remove the wheel cylinder from the support plate. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Brake Backing Plate - Removal > Page 4296 9. If equipped with a wheel speed sensor, remove the screw (1) fastening the wheel speed sensor head (3) in the rear of the hub and bearing (2). Remove the sensor head from the hub and bearing. 10. Remove the four bolts (8) securing the hub and bearing (5), support plate (2), and spacer (7) to the trailing link (1). 11. Remove the hub and bearing (3), support plate (2), and spacer (1) as an assembly from the trailing link. Separate the spacer and hub and bearing from the support plate once removed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Brake Backing Plate - Removal > Page 4297 Backing Plate: Service and Repair Brake Backing Plate - Installation INSTALLATION 1. Assemble the hub and bearing (3) through the support plate (2) and install the spacer (1) on the rear of the assembly. 2. Install the hub and bearing (3), support plate (2), and spacer (1) as an assembly on the trailing link. NOTE: When performing the following step, use NEW mounting bolts or clean and apply Mopar(R) Stud AND Bearing Mount Adhesive or equivalent to the original mounting bolt threads before reuse. 3. Install the four bolts (8) securing the hub and bearing (5), support plate (2), and spacer (7) to the trailing link (1). Tighten the mounting bolts to 105 Nm (77 ft. lbs.). 4. Insert the parking brake cable into its mounting hole in the brake support plate. Push the cable housing in until the retainer's fingers lock into place. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Brake Backing Plate - Removal > Page 4298 5. If equipped with a wheel speed sensor, Install the wheel speed sensor head (3) into the rear of the hub and bearing (2). Install the wheel speed sensor head mounting screw (1). Tighten the screw to 10 Nm (89 in. lbs.). 6. Install the wheel cylinder onto the brake support plate. Install and tighten the mounting screws (1) to 13 Nm (115 in. lbs.). 7. Connect the brake tube (2) to the wheel cylinder (1). Tighten the tube nut to 17 Nm (150 in. lbs.). 8. Lubricate shoe contact areas on support plate and anchor using Mopar(R) Brake Lubricant or equivalent. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Brake Backing Plate - Removal > Page 4299 NOTE: Inspect the brake shoes before installation. See: Brake Shoe/Service and Repair/Procedures/Inspection 9. Install the drum brake shoes (6) and drum (4). Adjust shoes as necessary. See: Brake Shoe/Service and Repair/Removal and Replacement/Installation 10. Install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 11. Slowly rotate the rear wheel and verify that the brake drum lightly drags on the shoes. 12. Lower the vehicle. 13. Remove the brake pedal holding tool. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Brake Backing Plate - Removal > Page 4300 14. Bleed the affected wheel cylinder as necessary. See: Brake Bleeding/Service and Repair 15. Road test the vehicle to ensure proper brake operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications BRAKE DRUM LIMITS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 4304 Brake Drum: Testing and Inspection BRAKE DRUM With the drum off the vehicle, measure the drum for diameter variation (oval shape). The diameter variation of the drum braking surface must not exceed specifications listed in the following table. Measure brake drum runout. Brake drum runout should be checked with the drum mounted on a brake lathe. Brake drum runout should not exceed specifications listed in the following table. If either of these measurements are not within specification, reface or replace the drum. See: Service and Repair/Procedures. Always replace the drum if machining will cause the diameter to exceed drum maximum diameter. All brake drums (2) are marked on the inside with the maximum allowable brake drum diameter (1). Maximum brake drum diameter can also be found in the following table. BRAKE DRUM LIMITS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures Brake Drum: Procedures BRAKE DRUM MACHINING If a brake drum is deeply scored or warped, it can be machined on a brake lathe equipped to machine brake drums. Follow the manufacturers instructions on the machining procedure. Measure the brake drum diameter before machining. If machining the drum will cause the drum to exceed maximum allowable diameter, do not machine the brake drum. It needs to be replaced. CAUTION: Do not machine the brake drum if it will cause the drum to exceed maximum allowable diameter. All brake drums (2) are marked with the maximum allowable brake drum diameter. All vehicles have it marked on the inside of the drum (1). When machining, make sure the feed rate for the final cut is set to deliver a fine finish. A fine finish helps to avoid a screw effect on the brake shoes when the brakes are applied. This final feed cut specification varies from lathe manufacturer to lathe manufacturer. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures > Page 4307 Brake Drum: Removal and Replacement Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Raise vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly. 3. Slide the brake drum (4) off the wheel mounting studs of the hub and bearing (5) and remove it from the vehicle. If the drum does not come off, further brake clearance can be obtained by backing off the brake adjuster screw. To do so, perform the following procedure. BACKING OFF SHOE ADJUSTMENT Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures > Page 4308 1. Remove the plug from the rear of the support plate below the wheel cylinder. 2. Insert a small screwdriver through the access hole (2) in the support plate, under the adjuster, against the lever pawl. The pawl is attached to and pivots from the rear brake shoe. 3. While pushing on the pawl with the screwdriver to disengage it from the adjuster wheel teeth, rotate the wheel (1) upward to back off the adjustment using another screwdriver or a brake adjuster tool. 4. Once the adjuster screw is backed off a sufficient amount, slide the drum off the wheel mounting studs. Installation INSTALLATION NOTE: Before installing drum, inspect brake shoe linings for wear, alignment, and contamination. Repair or replace as necessary. NOTE: If rust or any foreign material is present on hub, drum or wheel mating surfaces, wet wire brush these areas to remove prior to assembly of parts. 1. Properly remove any buildup formed along outer edge of drum's machined braking surface. 2. Adjust the brake shoes-to-drum diameter using a brake shoe gauge See: Brake Shoe/Adjustments. 3. Slide the brake drum (4) onto the wheel mounting studs on the hub and bearing (5). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures > Page 4309 4. Install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 5. Lower the vehicle. 6. Road test the vehicle stopping in both forward and reverse directions. The automatic-adjuster will continue to adjust the brakes as necessary during the road test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments Brake Shoe: Adjustments DRUM BRAKE SHOE ADJUSTMENT NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Verify the parking brake lever is in the fully released position. 2. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair NOTE: Perform the following steps on each rear drum brake assembly as necessary. 3. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. 4. Remove the brake drum (4). See: Brake Drum/Service and Repair/Removal and Replacement/Removal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Page 4313 5. Using a Brake Shoe Gauge C-3919 (1) or equivalent, measure the inside diameter of the brake drum at the center of the shoe contact area. Tighten the Gauge setscrew at this measurement. 6. Place the opposite side of the brake shoe gauge (2) over the brake shoes (1) as shown. 7. Adjust the shoe diameter to the setting on the gauge. To adjust the shoe diameter, turn the adjuster wheel using a screwdriver inserted through the adjusting hole in the rear of the shoe support plate. Once the tip of the screwdriver contacts the adjuster wheel teeth, move the handle of tool upward using the support plate as a pivot to adjust the shoes outward. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Page 4314 8. If at any time the adjustment needs to be backed off, perform the following: a. Remove the plug from the rear of the support plate below the wheel cylinder. b. Insert a small screwdriver through the access hole (2) in the support plate, under the adjuster, against the lever pawl. The pawl is attached to and pivots from the rear brake shoe. c. While pushing on the pawl with the screwdriver to disengage it from the adjuster wheel teeth, rotate the wheel (1) upward to back off the adjustment using another screwdriver or a brake adjuster tool. 9. Once the shoe diameter is set, remove the tool and install the brake drum (4). See: Brake Drum/Service and Repair/Removal and Replacement/Installation 10. Turn the brake drum. A slight drag should be felt while rotating the drum. If not, repeat the above procedure. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Page 4315 11. Install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 12. After adjusting both rear drum brakes as necessary, lower the vehicle. 13. Apply and release the parking brake lever one time after the adjustment process is completed checking parking brake operation. 14. Road test the vehicle stopping in both forward and reverse directions. The automatic-adjuster will continue to adjust the brakes as necessary during the road test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures Brake Shoe: Procedures Cleaning CLEANING WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. Inspection INSPECTION Inspect the shoe linings. Rear brake shoe linings should show contact across the entire width of the lining and also from the heel to the toe of the lining. Replace the shoes if noted otherwise. Brake shoes with lack of contact at the toe or heel of the brake shoe lining may be improperly ground. Clean and inspect the brake support plate and shoe adjuster screw. Apply a thin coat of Mopar(R) Multi-Purpose Grease or equivalent to the threads of the self-adjuster. Replace the adjuster screw if it is corroded. NOTE: Adjuster screws are different side-to-side. Left side adjuster screws have left-hand threads and right side adjuster screws have right-hand threads. Inspect the return springs and hold-down spring clips. If the existing brake shoe return springs or hold-down spring clips have been overheated or damaged, replace them. Overheating indications are paint discoloration or distorted end coils. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 4318 Brake Shoe: Removal and Replacement Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . NOTE: Make sure parking brake is in "released" position before raising vehicle. 1. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair NOTE: Perform 2 through 16 on each side of the vehicle to complete shoe set removal. It may be easier to install the new components on the first side of the vehicle before disassembling the opposite side so it may be used as a reference guide for proper installation. 2. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. 3. Remove the brake drum (4). See: Brake Drum/Service and Repair/Removal and Replacement/Removal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 4319 4. Remove the lower shoe spring (3). 5. Compress and remove the hold-down spring (4) retaining the rear shoe to the support plate. 6. Pull the rear shoe (4) away from the anchor (3) allowing better access to the parking brake cable (2) connection at the lever (1). 7. Compress the cable return spring, then remove the parking brake cable from the parking brake lever. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 4320 8. Compress and remove the hold-down spring (2) retaining the front shoe to the support plate. 9. Remove both brake shoes from the wheel cylinder. 10. Remove both shoes and remaining parts as an assembly (3) through the opening between the wheel cylinder (1) and support plate hub and bearing. 11. Place the shoe assembly outboard-side-up on a flat surface. 12. Remove the adjuster spring (2) from the leading shoe (3) and the lever pawl (1). 13. Remove the lever pawl (1) from the pivot on the rear shoe (5). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 4321 14. Flip the shoe assembly over to show the inboard side. 15. Remove the upper shoe return spring (1). 16. Remove the adjuster (5) from the shoes and parking brake lever (2). Installation INSTALLATION NOTE: Perform 1 through 21 on each side of vehicle to complete shoe set installation, then proceed to 22. 1. Lubricate shoe contact areas on support plate and anchor using Mopar(R) Brake Lubricant or equivalent. 2. Lubricate the adjuster screw threads with Mopar(R) Brake Lubricant or equivalent. Turn adjuster wheel in until it is completely seated. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 4322 NOTE: Right side drum brake shown. Left side is a mirror image. 3. Place one front shoe (6) and one rear shoe (3) inboard-side-up on a flat surface. (rear shoe has parking brake lever attached to it). 4. Install the adjuster (5), adjuster wheel toward the rear, between the two brake shoes. Make sure the wide notch in the rear fork aligns with the parking brake lever (2). 5. Install the upper return spring (1) as shown. 6. Flip the shoe assembly over to show the outboard side. 7. Install the lever pawl (1) onto the pivot located on the rear shoe (5). 8. Install the adjuster spring (2) between the front shoe (3) and the lever pawl (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 4323 9. Install the pre-assembled brake shoe assembly (3) through the opening between the wheel cylinder (1) and support plate hub and bearing. 10. Insert the upper tips of the brake shoes into the grooves of the wheel cylinder (1) pistons. 11. Position the bottom of the front shoe against the anchor pin (5). 12. Install a shoe hold-down pin from the rear, through the support plate and the front shoe. 13. Compress and install the hold-down spring (2) retaining the front shoe to the support plate. 14. Compress the parking brake cable return spring, then carefully install the cable onto the parking brake lever. Release the spring guiding it beneath the retaining tab on the lever. 15. Position the bottom of the rear shoe against the anchor pin (5). 16. Install a shoe hold-down pin from the rear, through the support plate and the rear shoe. 17. Compress and install the hold-down spring (4) retaining the rear shoe to the support plate. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Procedures > Page 4324 18. Install the lower shoe spring (3). 19. Adjust the brake shoes to the drum diameter using a brake shoe gauge. See: Adjustments 20. Install the brake drum (4). See: Brake Drum/Service and Repair/Removal and Replacement/Installation 21. Install tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 22. Slowly rotate both rear wheels and verify that the brake drums lightly drag on the shoes. Further adjustments may be done using the adjustment procedure as necessary. See: Adjustments 23. Lower the vehicle. 24. Road test vehicle stopping in both forward and reverse directions. The automatic-adjuster will continue to adjust brakes as necessary during road test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Procedures Wheel Cylinder: Procedures INSPECTION With the brake drum removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders must be replaced. If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake shoes must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 4329 Wheel Cylinder: Removal and Replacement Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Using a brake pedal holder, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir. 2. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 3. Remove the wheel mounting nuts (3), then the tire and wheel assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 4330 4. Access and remove the drum brake shoes (6) from the support plate (2). See: Brake Shoe/Service and Repair/Removal and Replacement/Removal 5. Disconnect the brake tube (2) at the wheel cylinder. 6. Remove the wheel cylinder attaching screws (1). 7. Remove the wheel cylinder from the support plate. Installation INSTALLATION 1. Install the wheel cylinder onto the brake support plate. Install and tighten the mounting screws (1) to 13 Nm (115 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 4331 2. Hand start the brake tube nut (2) into the wheel cylinder (1). Tighten the tube nut to 17 Nm (150 in. lbs.). NOTE: Inspect the brake shoes before installation. See: Brake Shoe/Service and Repair/Procedures/Inspection 3. Install the drum brake shoes (6) and drum. Adjust shoes as necessary. See: Brake Shoe/Service and Repair/Removal and Replacement/Installation 4. Install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 5. Slowly rotate the rear wheel and verify that the brake drum lightly drags on the shoes. 6. Lower the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 4332 7. Remove the brake pedal holder. 8. Bleed the wheel cylinder as necessary. See: Brake Bleeding/Service and Repair 9. Road test the vehicle to make sure the brakes operate correctly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding Brake Bleeding: Service and Repair Base Brake Bleeding BASE BRAKE BLEEDING NOTE: For bleeding the ABS hydraulic system, refer to Antilock Brake System Bleeding in the Antilock Brake System section. See: Antilock Brake System Bleeding CAUTION: Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder reservoir. CAUTION: Use only Mopar(R) brake fluid or an equivalent from a fresh, tightly sealed container. Brake fluid must conform to DOT 3 specifications. NOTE: For bleeding of the Antilock Brake System, See: . Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process. This will only increase the amount of air in the system and make additional bleeding necessary. Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air into the brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit sequence for bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic system. - Left rear wheel - Right front wheel - Right rear wheel - Left front wheel MANUAL BLEEDING NOTE: To bleed the brakes manually, the aid of a helper will be required. 1. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With the pedal in the down position, open the bleeder screw at least one full turn. 4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 4338 6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir (2) to make sure it does not go dry. 7. Check and adjust brake fluid level to the FULL mark. 8. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. 9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. PRESSURE BLEEDING NOTE: Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. 1. Attach Master Cylinder Cap 6921 (2) in place of the filler cap on the master cylinder reservoir (3). 2. Attach Bleeder Tank C-3496-B (1) or an equivalent, to the Master Cylinder Cap 6921 (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 4339 3. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2) containing enough fresh brake fluid to submerge the end of the hose. 4. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 5. After approximately 120-240 ml (4-8 ounces) of fluid have been bled through the brake circuit and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw. 6. Repeat this procedure at all the remaining bleeder screws. 7. Check and adjust brake fluid level to the FULL mark on the reservoir (2). 8. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary. 9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 4340 Brake Bleeding: Service and Repair Antilock Brake System Bleeding ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Brake systems with ABS must be bled as two independent braking systems. The non-ABS portion of the brake system with ABS is to be bled the same as any non-ABS system. The ABS portion of the brake system must be bled separately. Use the following procedure to properly bleed the brake hydraulic system including the ABS. NOTE: During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add Mopar(R) DOT 3 brake fluid as required. BLEEDING When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the scan tool to the diagnostics connector. The diagnostic connector is located under the lower steering column cover to the left of the steering column. 3. Using the scan tool, check to make sure the ABM does not have any fault codes stored. If it does, clear them. WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube (1) must be attached to the bleeder screws and submerged in a clear container filled part way with clean brake fluid (2). Direct the flow of brake fluid away from yourself and the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the bleeder screws when opened. NOTE: Pressure bleeding is recommended to bleed the base brake system to ensure all air is removed from system. Manual bleeding may also be used, but additional time is needed to remove all air from system. 4. Bleed the base brake system. See: 5. Using the scan tool, select ECU VIEW, followed by ABS MISCELLANEOUS FUNCTIONS to access bleeding. Follow the instructions displayed. When finished, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Base Brake Bleeding > Page 4341 7. Fill the master cylinder fluid reservoir (1) to the FULL level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures Brake Caliper: Procedures Front CLEANING WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R) Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. Rear CLEANING WARNING: Chrysler LLC does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R) Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. Front INSPECTION Inspect the disc brake caliper for the following: - Brake fluid leaks in and around piston boot area - Ruptures, brittleness or damage to the piston dust boot If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Rear INSPECTION Inspect the disc brake caliper for the following: - Brake fluid leaks in and around boot area and inboard lining - Ruptures, brittleness or damage to the piston dust boot - Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4346 Brake Caliper: Removal and Replacement Front REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch (25 mm) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir when the lines are opened. 2. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 3. Remove the wheel mounting nuts (3), then the tire and wheel assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4347 4. Remove the banjo bolt (4) connecting the brake flex hose (2) to the brake caliper (5). There are two washers (3) that will come off with the banjo bolt. Discard the washers. NOTE: When removing the caliper guide pin bolts (2, 3) note that one (upper) has a special sleeve on the end. It is important that this bolt be installed in the upper mounting hole when the caliper is installed. 5. Remove the two brake caliper guide pin bolts (2, 3). 6. Slide the disc brake caliper (4) from the disc brake adapter bracket (1) and brake pads and remove. Rear REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4348 1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir while the lines are disconnected. 2. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 3. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. 4. Unthread the brake tube nut (2) at the rear flex hose. 5. Remove the clip (3) securing the rear flex hose to the trailing link mounted bracket. Remove the flex hose from the bracket. 6. Unthread and remove the brake flex hose (4) from the brake caliper (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4349 NOTE: When removing the caliper guide pin bolts (2, 3), note that one bolt has a special sleeve on the tip and the other does not. Depending on the build date (vehicle built before or after 7/27/06), this special sleeve bolt (3) can be located in either the top or bottom location. When installing, make sure the bolts are put back in the same locations as when removed to avoid NVH issues. 7. Remove the two brake caliper guide pin bolts (2, 3). 8. Slide and remove the disc brake caliper (1) with outboard brake pad attached from the disc brake adapter bracket, inboard brake pad and rotor. 9. Remove the outboard brake pad from the caliper by prying the brake pad retaining clip over the raised area on the caliper. Slide the brake pad off of the brake caliper. Front INSTALLATION 1. Completely retract the caliper piston back into the bore of the caliper. Use a C-clamp to retract the piston. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston. CAUTION: Use care when installing the caliper (4) onto the adapter bracket (1) to avoid damaging the guide pin boots. 2. Install the disc brake caliper over the brake pads on the brake caliper adapter bracket. NOTE: When installing the caliper guide pin bolts (2, 3) make sure that the one that has a special sleeve on the end is installed in the upper mounting hole. 3. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper (with special sleeve) (2) and lower (3) caliper guide pin bolts. Tighten the guide pin bolts to 43 Nm (32 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4350 4. Install the banjo bolt (4) connecting the brake flex hose (2) to the brake caliper (5). Install NEW washers (3) on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to 24 Nm (18 ft. lbs.). 5. Install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Remove the brake pedal holding tool. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4351 8. Bleed the caliper as necessary. See: Brake Bleeding/Service and Repair 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. Rear INSTALLATION 1. If not already performed, completely retract the caliper piston back into the piston bore of the caliper. Use a C-clamp to retract the piston. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston. 2. Slide the outboard brake pad onto the caliper. Be sure the retaining clip is squarely seated in the depressed areas on the caliper beyond the raised retaining bead. CAUTION: Use care when installing the caliper onto the disc brake adapter to avoid damaging the guide pin boots. 3. Install the disc brake caliper with outboard brake pad attached over the inboard brake pad and rotor, onto the brake caliper adapter bracket. NOTE: When installing the caliper guide pin bolts (2, 3), make sure the bolts are put back in the same locations as when removed to avoid NVH issues. Depending on the build date (vehicles built before or after 7/27/06) and services performed, the location of the bolt with the special sleeve on the tip (3) can vary. 4. Align the caliper guide pin bolt holes with the adapter bracket. Install the lower (2) and upper (with special sleeve) (3) caliper guide pin bolts. Tighten the guide pin bolts to 43 Nm (32 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4352 5. Thread the rear brake flex hose (4) into the brake caliper (1). Tighten the flex hose fitting at the caliper to 15 Nm (133 in. lbs.). 6. Route and install the brake flex hose into the trailing link mounted bracket. Install the clip (3) securing the flex hose to the bracket. 7. Thread the brake tube nut (2) into brake flex hose. Tighten the brake tube nut to 17 Nm (150 in. lbs.). 8. Install tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. 10. Remove the brake pedal holding tool. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4353 11. Bleed the caliper as necessary. See: Brake Bleeding/Service and Repair 12. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4354 Brake Caliper: Overhaul Rear DISASSEMBLY NOTE: Before disassembling the brake caliper, remove it from the vehicle. See: Removal and Replacement/Disc Brake Caliper - Removal NOTE: Before disassembling the brake caliper, clean and inspect it. See: Procedures/Disc Brake Caliper - Cleaning See: Procedures/Disc Brake Caliper - Inspection 1. With finger tip, trace around the outside perimeter of the piston dust boot to find the ends of the boot snap-ring. 2. Using a small screwdriver (2) or like tool, carefully remove the boot snap-ring (1) making sure not to damage the dust boot, piston or piston bore. 3. Carefully pull the piston dust boot away from the caliper boot groove. WARNING: Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 4. Mount the caliper in a vise equipped with protective jaws. WARNING: Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure. 5. Place a wooden block (2) in the caliper as shown. 6. As necessary, apply low pressure compressed air to the caliper fluid inlet in short spurts to force the piston (1) out. 7. Remove the piston (with dust boot) from the caliper. 8. Remove the dust boot from the piston and discard it. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4355 CAUTION: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. 9. Using a soft tool such as a plastic trim stick (2), work the piston seal (1) out of its groove (3) in the caliper piston bore. Discard the used seal. 10. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 11. Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Front DISASSEMBLY NOTE: Before disassembling the brake caliper, remove it from the vehicle. See: Removal and Replacement/Disc Brake Caliper - Removal NOTE: Before disassembling the brake caliper, clean and inspect it. See: Procedures/Disc Brake Caliper - Cleaning See: Procedures/Disc Brake Caliper - Inspection WARNING: Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 1. Mount the caliper in a vise equipped with protective jaws. WARNING: Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure. 2. Place a wooden block (1) in the caliper as shown. 3. If necessary, apply low pressure compressed air to the caliper fluid inlet in short spurts to force the piston out. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4356 4. Remove the piston from the caliper. 5. Remove the dust boot from the piston and discard it. CAUTION: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. 6. Using a soft tool such as a plastic trim stick (1), work the piston seal (2) out of its groove in caliper piston bore. Discard the used seal. 7. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect both the piston and bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Rear ASSEMBLY NOTE: Always have clean hands when assembling a brake caliper. NOTE: Always use fresh, clean brake fluid when assembling a brake caliper. NOTE: Never use an old piston seal. 1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper piston bore. The seal (1) should be started at one area of the groove and gently worked around into the groove using only clean finger tips to seat it. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4357 2. Coat the NEW piston dust boot (1) with clean brake fluid leaving a generous amount inside the boot. 3. Position the dust boot over the top of the piston (2) and into the piston groove. Make sure the side of the dust boot with the outer lip (3) for the boot snap-ring is positioned upward as shown. 4. Coat the piston with clean brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. 5. Insert the piston into the caliper bore, carefully pushing it past the piston seal using hand pressure. Push the piston in until it bottoms in the caliper bore. 6. With finger tips, seat the dust boot lip (1) into the boot groove in the caliper bore. Trace around the outside perimeter of the dust boot with a finger tip making sure the lip is properly seated in the groove and not much air is trapped behind the boot. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4358 7. Position one end of the boot snap-ring (1) inside the boot outer lip (2), then making a circular motion, walk the snap-ring around the boot lip, completely installing and seating it. 8. Inspect whether the two ends of the boot snap-ring are not overlapping one another. If they are, push the snap ring and dust boot further into groove removing any overlap of the snap-ring. 9. Install the caliper on the vehicle and bleed the brakes as necessary. See: Removal and Replacement/Disc Brake Caliper - Installation Front ASSEMBLY NOTE: Always have clean hands when assembling a brake caliper. NOTE: Always use fresh, clean brake fluid when assembling a brake caliper. NOTE: Never use an old piston seal. 1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper bore. The seal (1) should be started at one area of the groove and gently worked around into the groove using only your clean fingers to seat it. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4359 2. Coat the NEW piston with clean brake fluid. 3. Coat the NEW piston boot with clean brake fluid leaving a generous amount inside the boot. 4. Position the dust boot over the lower section of the piston. 5. Extend the dust boot below the bottom of the piston and guide the lip seal into the groove in the caliper piston bore. CAUTION: Force applied to the piston (1) to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. 6. Install the piston (1) into the bore, carefully pushing it past the piston seal using hand pressure. Push the piston in until it bottoms in the caliper bore and the dust boot lip seal falls into the groove near the top of the piston. 7. Install the caliper on the vehicle and bleed the brakes as necessary. See: Removal and Replacement/Disc Brake Caliper - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4364 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 4365 Brake Fluid: Specifications Mopar DOT 3, SAE J1703 should be used. If DOT 3, SAE J1703 brake fluid is not available, then DOT 4 is acceptable. Use only recommended brake fluids or equivalent. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 4366 Brake Fluid: Description and Operation BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar(R) Brake Fluid or equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 4367 Brake Fluid: Testing and Inspection BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid including: the master cylinder and reservoir; proportioning valves (non-ABS); caliper seals; wheel cylinder seals; ABS hydraulic control unit; and all hydraulic fluid hoses. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 4368 Brake Fluid: Service and Repair BRAKE FLUID LEVEL CHECKING NOTE: Brake fluid level should be checked a minimum of twice a year. Master cylinder reservoirs (2) are marked, FULL and ADD, indicating the allowable brake fluid level range in the master cylinder fluid reservoir. CAUTION: Use only Mopar(R) Brake Fluid DOT 3 Motor Vehicle or equivalent from a tightly sealed container. Do not use petroleum-based fluid because seal damage in the brake system will result. See: Specifications NOTE: Although there is a range, the preferred level is FULL. 1. Remove the cap (1). 2. Adjust the brake fluid level to the FULL mark listed on the side of the master cylinder fluid reservoir (2) as necessary. Do not overfill the system. 3. Install the cap (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4372 Brake Fluid Level Sensor/Switch: Diagrams Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-BRAKE FLUID LEVEL - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4373 Brake Fluid Level Sensor/Switch: Description and Operation DESCRIPTION The brake fluid level switch (2) is mounted through the center of the fluid reservoir (1). The switch can be serviced separately from the master cylinder fluid reservoir. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Brake Fluid Level Switch - Removal Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Switch - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Remove the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. 2. Push together the retaining tabs (1) holding the brake fluid level switch in place in the brake fluid reservoir (2). 3. Pull the brake fluid level switch out the right side of the reservoir. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Brake Fluid Level Switch - Removal > Page 4376 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Switch - Installation INSTALLATION 1. Align the brake fluid level switch with its mounting hole on the right side of the master cylinder brake fluid reservoir. Push the switch into the fluid reservoir until the switch retaining tabs (1) are expanded on the opposite side of the reservoir (2), locking it in place. 2. Connect the wiring harness connector (1) to the switch (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation Brake Hose/Line: Description and Operation DESCRIPTION The brake tubes are steel with a corrosion-resistant nylon coating applied to the external surfaces. The flex hoses used at each wheel brake are made of reinforced rubber with fittings at each end. The fitting at each front brake caliper is the banjo-type and requires a special banjo bolt and copper washers. The fitting at each rear brake caliper is a screw-in type fitting. Rear drum brake vehicles use a standard tube nut fitting at each wheel cylinder. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation > Page 4380 Brake Hose/Line: Service and Repair INSPECTION Brake tubing should be inspected periodically for evidence of physical damage or contact with moving or hot components. Flexible rubber hose is used at both the front and rear wheel brakes. Inspection of the flexible brake hoses should be performed whenever the brake system is serviced and every 12,000 km (7,500 miles) or 12 months, whichever comes first. Inspect hydraulic brake hoses for surface cracking, scuffing, or worn spots. If the fabric casing of the hose becomes exposed due to cracks or abrasions in the hose cover, the hose should be replaced immediately. Eventual deterioration of the hose can take place with possible burst failure. Faulty installation can cause twisting, resulting in wheel, tire, or chassis interference. NOTE: This vehicle is equipped with more than one size (diameter) brake tube depending on location on the vehicle. If a brake tube must be replaced, always use the same size brake tubing as that being replaced. Never use under-size brake tubing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Description Brake Proportioning/Combination Valve: Description and Operation Description DESCRIPTION NOTE: Only vehicles without antilock brakes have proportioning valves. Vehicles with antilock brakes have Electronic Variable Brake Proportioning (EVBP) that is built into the Integrated Control Unit (ICU). On the non-antilock master cylinder (1), two screw-in proportioning valves (2, 3) are screwed directly into the rear brake outlet ports. The chassis brake tubes leading to the rear brakes attach to the outlets of the proportioning valves. One proportioning valve controls each rear brake. The proportioning valves are not identical and cannot be interchanged. The proportioning valve that threads into the primary port (3) has M10 x 1 threads going into the master cylinder (1). The proportioning valve that threads into the secondary port (2) has M12 x 1 threads going into the master cylinder (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Description > Page 4385 Brake Proportioning/Combination Valve: Description and Operation Operation OPERATION Proportioning valves balance front to rear braking by controlling the brake fluid hydraulic pressure to the rear brakes above a preset level (split point). Under light pedal application, the proportioning valve allows normal fluid flow to the rear brakes. Under higher pedal effort, the valve reduces fluid pressure to the rear brakes. This helps prevent rear wheel skid tendencies. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Removal Brake Proportioning/Combination Valve: Service and Repair Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Using a brake pedal holder, depress the brake pedal past its first one inch (25 mm) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir. NOTE: To access the lower (left rear) proportioning valve, it may help to remove the air cleaner cover and hose to the throttle body. 2. Disconnect the brake tube (1 or 2) from the proportioning valve requiring removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Removal > Page 4388 3. Unscrew the proportioning valve (2 or 3) from the master cylinder (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Removal > Page 4389 Brake Proportioning/Combination Valve: Service and Repair Installation INSTALLATION 1. Install the proportioning valve (2 or 3) in its master cylinder (1) port. Tighten the proportioning valve to 30 Nm (22 ft. lbs.). 2. Install the correct brake tube (1 or 2) to the proportioning valve. Tighten the tube nut to 17 Nm (150 in. lbs.). 3. Remove the brake pedal holder. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Removal > Page 4390 4. Bleed the affected brake line(s). See: Brake Bleeding/Service and Repair 5. Road test the vehicle to ensure proper operation of the brakes. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) - Description Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control unit (HCU) - Description DESCRIPTION The Hydraulic Control Unit (HCU) is mounted to the Antilock Brake Module (ABM) as part of the Integrated Control Unit (ICU). The HCU controls the flow of brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on the HCU to empty the accumulators during an ABS stop and supply build pressure to the brakes during a traction control or ESP event. VALVES AND SOLENOIDS The valve block contains four inlet valves and four outlet solenoid valves. The inlet valves are spring-loaded in the open position and the outlet valves are spring-loaded in the closed position during normal braking. The fluid is allowed to flow from the master cylinder to the wheel brakes. During an ABS stop, these valves cycle to maintain the proper slip ratio for each wheel. The inlet valve closes preventing further pressure increase and the outlet valve opens to provide a path from the wheel brake to the HCU accumulators and pump/motor. This releases (decays) pressure from the wheel brake, thus releasing the wheel from excessive slippage. Once the wheel is no longer slipping, the outlet valve is closed and the inlet valve is opened to reapply (build) pressure. If the ABS includes the traction control feature, there are four other valves in the HCU. Two Traction Control (TC) (or ESP) valves, mounted in the HCU valve block, are normally in the open position and close only when the traction control is applied. There are also two normally closed shuttle valves which open during traction control and ESP events to provide a direct fluid path from the brake fluid reservoir to the inlet of the HCU pump. These TC valves are used to isolate the rear (non-driving) wheels of the vehicle from the hydraulic pressure that the HCU pump/motor is sending to the front (driving) wheels when traction control is being applied. The rear brakes need to be isolated from the master cylinder when traction control is being applied so the rear wheels do not drag. BRAKE FLUID ACCUMULATORS There are two fluid accumulators in the HCU: one for the primary hydraulic circuit, and one for the secondary hydraulic circuit. Each hydraulic circuit uses a 3 cc accumulator. The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during an ABS cycle. This stored fluid is used by the pump/motor to provide build pressure for the brake hydraulic system. When the antilock stop is complete, the accumulators are drained by the pump/motor. There are two noise dampening chambers in the HCU on this vehicle equipped with traction control. PUMP/MOTOR There are two pump assemblies in the HCU: one for the primary hydraulic circuit, and one for the secondary hydraulic circuit. Both pumps are driven by a common electric motor. This DC-type motor is integral to the HCU and is controlled by the ABM. Brake fluid is released to the accumulators when the outlet valve is opened during an antilock stop. The pump mechanism consists of two opposing pistons operated by an eccentric camshaft. In operation, these pistons are used to purge fluid from the accumulators back into the master cylinder circuits. When the antilock stop is complete, the pump/motor drains the accumulators. The pump motor is also used to build pressure when the system goes into Electronic Stability Program (ESP(R)) and traction control mode. The ABM may turn on the pump/motor when an antilock stop is detected. The pump/motor continues to run during the antilock stop and is turned off after the stop is complete. Under some conditions, the pump/motor runs to drain the accumulators during the next drive-off. The pump/motor is not a serviceable item; if it requires replacement, the HCU must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) - Description > Page 4395 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Integrated Control Unit (ICU) - Description DESCRIPTION The Hydraulic Control Unit (HCU) (2) and the Antilock Brake Module (ABM) (1) used with this antilock brake system are combined (integrated) into one unit, which is called the Integrated Control Unit (ICU). The ICU (1) is located in the engine compartment, mounted to the right side body frame rail near the strut tower. Two different ICU's are used on this vehicle depending on whether or not the vehicle is equipped with traction control and Electronic Stability Program (ESP(R)). The HCU on a vehicle equipped with traction control or ESP(R) has a valve block that is approximately one inch longer than a HCU on a vehicle that is equipped with ABS only. The ABS-only ICU consists of the following components: the ABM, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), valve block, fluid accumulators, a pump, and an electric motor. The ABS with ESP(R) and All-Speed Traction Control ICU consists of the following components: the ABM, eight (build/decay) solenoid valves, two traction control solenoid valves, two shuttle valves, valve block, fluid accumulators, a pump, and an electric pump/motor. The replaceable components of the ICU are the HCU and the ABM. No attempt should be made to service any components of the HCU or ABM. For additional information on the ABM, See: Antilock Brakes / Traction Control Systems/Electronic Brake Control Module/Description and Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) - Description > Page 4396 Operation/Anti-Lock Brake System Module - Description. For additional information on the HCU, See: Hydraulic Control unit (HCU) - Description - DESCRIPTION). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) - Description > Page 4397 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Integrated Control Unit (ICU) - Operation OPERATION For information of the ICU, refer to these individual components of the ICU: - ANTILOCK BRAKE MODULE (ABM) See: Antilock Brakes / Traction Control Systems/Electronic Brake Control Module/Description and Operation/Anti-Lock Brake System Module - Description - HYDRAULIC CONTROL UNIT (HCU) See: Hydraulic Control unit (HCU) - Description DESCRIPTION) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement Hydraulic Control Assembly - Antilock Brakes: Removal and Replacement Hydraulic Control unit (HCU) - Installation INSTALLATION To install the HCU, assemble and install the ICU. See: Overhaul/Integrated Control Unit (ICU) Assembly See: Integrated Control Unit (ICU) - Installation Integrated Control Unit (ICU) - Removal GAS ENGINE NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Disconnect and isolate battery negative cable from battery post. 2. Using a brake pedal holding tool as shown, depress the brake pedal past its first 25 mm (1 inch) of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir while the lines are disconnected. 3. Remove the engine appearance cover. 4. Loosen lower and upper mounting nuts, then remove the exhaust heat shield from the dash panel. 5. Pull the brake tube bundle routing clips (with tubes) loose from studs on the dash panel. 6. Remove the primary (4) and secondary (1) brake tubes (from master cylinder) at the hydraulic control unit (7). 7. Remove the remaining brake tubes (2, 3, 5, 6) at the hydraulic control unit (7). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4400 8. Remove the screw (1) fastening the power steering pressure hose routing clamp (2) to the exhaust manifold. NOTE: Use this figure in the following step to release the ABM harness connector cover. It shows the location of the release tabs. 9. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so: a. Depress the tabs on each side of the connector cover, then b. Pull outward and upward on the lower half of the cover until it locks into position pointing straight outward (2). The connector can then be Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4401 pulled straight outward off the ABM (1). 10. Loosen, but do not remove, the two mounting screws (2) attaching the ICU (1) mounting bracket to the body. 11. Lift the ICU and mounting bracket (1) off the mounting screws (2). 12. Move the brake tubes around as necessary without bending them and remove the ICU with bracket through the opening between the A/C lines and the exhaust manifold. 13. To separate the ABM from the HCU, See: Overhaul/Integrated Control Unit (ICU) Disassembly - DISASSEMBLY). Integrated Control Unit (ICU) - Installation GAS ENGINE 1. Install the ICU with bracket (1) through the opening between the A/C lines and the exhaust manifold using the opposite of how it was removed. 2. Place the mounting bracket for the ICU (1) over the mounting screws (2) and hang the assembly in place. Tighten the two mounting screws (2) to 23 Nm (17 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4402 CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly installed in the connector. 3. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover, locking the connector in place. 4. Install the four chassis brake tubes (2, 3, 5, 6) brake tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 Nm (150 in. lbs.). 5. Install the primary (4) and secondary (1) brake tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 Nm (150 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4403 6. Position the power steering pressure hose routing clamp (2) on the exhaust manifold and install the mounting screw (1). Tighten the mounting screw to 9 Nm (80 in. lbs.). 7. Push the brake tube bundle routing clips (with tubes) onto the studs on the dash panel. 8. Install the heat shield on the dash panel and tighten the lower and upper mounting nuts. 9. Remove the brake pedal holding tool. 10. Install the engine appearance cover. 11. Connect the battery negative cable to the battery post. It is important that this be performed properly. See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection 12. Hook up the scan tool to initialize the ABM and perform the following: a. Clear any faults. b. Fill the master cylinder to the proper fill level and bleed the base and ABS hydraulic systems. See: Brake Bleeding/Service and Repair c. Check for leaks. d. Perform the ABS Verification Test, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test and road test the vehicle. Hydraulic Control unit (HCU) - Removal REMOVAL To remove the HCU, the ICU must be removed and disassembled. See: Integrated Control Unit (ICU) - Removal See: Overhaul/Integrated Control Unit (ICU) - Disassembly Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4404 Hydraulic Control Assembly - Antilock Brakes: Overhaul Integrated Control Unit (ICU) - Assembly ASSEMBLY 1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant. 2. If the seals (1) on the solenoid valve stems (2) are not new, replace them all. Each of the solenoid valve stem seals must be new to keep out moisture and debris; do not reuse solenoid valve stem seals. 3. Replace the pump/motor connector O-ring (1) if it is not new. Be sure the O-ring is properly seated in the mounting groove (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4405 4. Align components and install the ABM (1) on the HCU (2). 5. If not equipped with ESP(R) or traction control, install the three screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2 Nm (17 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4406 6. If equipped with ESP(R) or traction control, install the four screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2 Nm (17 in. lbs.). 7. If necessary, install the mounting pins (1) in the ICU (2) and tighten to 11 Nm (97 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4407 8. If the mounting bracket (3) needs to be installed on the ICU (1), install the mounting pins in the ICU as necessary and tighten to 11 Nm (97 in. lbs.). Insert the mounting pins into the grommets mounted in the bracket, then install the single mounting bolt (2). Tighten the mounting bolt to 11 Nm (97 in. lbs.). 9. Install the ICU in the vehicle. See: Removal and Replacement/Integrated Control Unit (ICU) Installation Integrated Control Unit (ICU) - Disassembly DISASSEMBLY 1. If the mounting bracket (3) needs to be removed from the ICU, remove the single mounting bolt (2), then slide the ICU's mounting pins out of the grommets in the bracket and remove the bracket. 2. Remove the mounting pins from the ICU. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4408 3. If not equipped with ESP(R) or traction control, remove the three screws (1) attaching the ABM (2) to the HCU. 4. If equipped with ESP(R) or traction control, remove the four screws (1) attaching the ABM (2) to the HCU. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 4409 5. Separate the ABM (1) from the HCU (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Master Cylinder - Description Brake Master Cylinder: Description and Operation Brake Master Cylinder - Description DESCRIPTION The master cylinder used on this vehicle is a Plunger II design supplied by Continental Teves. The bore diameter for all applications is 20.6 mm (0.812 in.). The non-ABS master cylinder (3) is a four-outlet design (one for each wheel brake). There are two ports at each piston. One feeds a front wheel brake while the other feeds the opposite side rear wheel brake. The rear wheel brake ports are drilled and threaded to accept screw-in proportioning valves. Both valves are threaded into the bottom of the master cylinder housing. All ABS master cylinders (3) are a two-outlet design and the brake tubes from these primary and secondary outlet ports lead directly to the Integrated Control Unit (ICU) before going to each wheel brake. All master cylinders mount to the power brake booster in the same manner. The master cylinder body is an anodized aluminum casting. It has a machined bore to accept the master cylinder pistons and also has threaded ports with seats for hydraulic brake tube connections. The master cylinder has the brake fluid reservoir mounted on top of it which gravity feeds brake fluid to the master cylinder when it is required. On manual transmission model vehicles the brake fluid reservoir also feeds the clutch hydraulic circuit. The reservoir is made of see-through plastic and it houses the brake fluid level switch. A removable brake fluid level switch is mounted in the right side. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Master Cylinder - Description > Page 4414 Brake Master Cylinder: Description and Operation Brake Master Cylinder - Operation OPERATION When the brake pedal is pressed, the master cylinder primary and secondary pistons apply brake pressure through the proportioning valves (on non-ABS vehicles) and chassis brake tubes to each brake assembly. The brake fluid reservoir supplies the brake hydraulic system with the necessary fluid to operate properly. The non-ABS master cylinder's primary outlet ports supply hydraulic pressure to the right front and left rear brakes while the secondary outlet ports supply hydraulic pressure to the left front and right rear brakes. ABS equipped master cylinder outlet ports supply hydraulic pressure to the ABS Integrated Control Unit (ICU) where it is distributed to the individual wheel brakes. The master cylinder reservoir cap diaphragm is slit to allow atmospheric pressure to equalize on both sides of the diaphragm. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures Brake Master Cylinder: Procedures MASTER CYLINDER BLEEDING NOTE: On vehicles without ABS this procedure is designed to be performed with the proportioning valves installed in the master cylinder. 1. Clamp the master cylinder in a vise with soft-jaw caps. 2. Master Cylinder without ABS - Attach the special tools for bleeding the master cylinder in the following fashion: a. Thread Bleeder Tube Adapter 8822-1 (1) into the primary outlet port of the master cylinder without a proportioning valve. Tighten Adapter to 17 Nm (150 in. lbs.). b. Thread Bleeder Tube Adapter 8822-2 (2) into the secondary outlet port of the master cylinder without a proportioning valve. Tighten Adapter to 17 Nm (150 in. lbs.). c. Thread Bleeder Tube Adapter 8822-1 (4) into the proportioning valve in the lower secondary outlet port of the master cylinder. Tighten Adapter to 17 Nm (150 in. lbs.). d. Thread Bleeder Tube Adapter 8822-2 (5) into the proportioning valve in the lower primary outlet port of the master cylinder. Tighten Adapter to 17 Nm (150 in. lbs.). e. Thread a Bleeder Tube 8358-1 (6) into each Adapter. Tighten tube nuts to 17 Nm (150 in. lbs.). f. Install Bleeder Tubes Adapter (3), Special Tool 9705, in place of the fill cap as shown. g. Flex and place the open ends of the Bleeder Tubes into open hose tips on Adapter 9705. Be sure Bleeder Tubes are inserted into Adapter 9705 far enough not to come loose during bleed procedure. 3. Master Cylinder with ABS - Attach the special tools for bleeding the master cylinder in the following fashion: a. Thread Bleeder Tube Adapters 8822-2 (3) into the primary and secondary outlet ports of the master cylinder. Tighten Adapters to 17 Nm (150 in. lbs.). b. Thread a Bleeder Tube 8358-1 (2) into each Adapter. Tighten tube nuts to 17 Nm (150 in. lbs.). c. Flex each Bleeder Tube and place the open ends into the neck of the master cylinder reservoir. Position the open ends of the tubes into the reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4417 NOTE: Make sure the ends of the Bleeder Tubes stay below the surface of the brake fluid in the reservoir at all times during the bleeding procedure. 4. Fill the brake fluid reservoir with fresh Mopar(R) Brake Fluid DOT 3 Motor Vehicle, or equivalent. See: Brake Fluid/Specifications 5. Using an appropriately sized wooden dowel as a pushrod, slowly press the pistons inward discharging brake fluid through the Bleeder Tubes, then release the pressure, allowing the pistons to return to the released position. Repeat this several times until all air bubbles are expelled from the master cylinder bore and Bleeder Tubes. 6. Remove the Bleeder Tubes and Adapters from the master cylinder and plug the master cylinder outlet ports. 7. Install the fill cap on the reservoir. 8. Remove the master cylinder from the vise. 9. Install the master cylinder on the vehicle. See: Removal and Replacement/Brake Master Cylinder Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4418 Brake Master Cylinder: Removal and Replacement With ABS WITH ABS NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved. 1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm. 2. Disconnect the negative (ground) cable from the battery and isolate the cable. 3. Disconnect the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. 4. Disconnect the primary (1) and secondary (2) brake tubes at the master cylinder outlet ports. Install plugs at all of the open brake tube outlets on the master cylinder. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4419 5. If equipped with a manual transaxle, remove the clamp and slide the clutch actuator hose (2) off the reservoir port (1). 6. Clean the area around where the master cylinder (2) attaches to the power brake booster (1) using a suitable brake cleaner such as Mopar(R) Brake Parts Cleaner or an equivalent. 7. Remove the two nuts (3) attaching the master cylinder (2) to the power brake booster (1). 8. Slide the master cylinder straight out of the power brake booster. Without ABS WITHOUT ABS NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . CAUTION: The vacuum in the power brake booster must be pumped down before removing the master cylinder to prevent the booster from sucking in any contamination. This can be done by pumping the brake pedal while the engine is not running until a firm brake pedal is achieved. 1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm. 2. Disconnect the negative (ground) cable from the battery and isolate the cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4420 3. Remove the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. 4. Disconnect the two front brake tubes (1, 2) from the master cylinder. Install plugs at the open brake tube outlets on the master cylinder. 5. Disconnect the two rear brake tubes (1, 2) from the proportioning valves on the master cylinder (3). Install plugs at the open brake tube outlets on the proportioning valves. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4421 6. If equipped with a manual transaxle, remove the clamp and slide the clutch actuator hose (2) off the reservoir port (1). 7. Clean the area around where the master cylinder (2) attaches to the power brake booster (1) using a suitable brake cleaner such as Mopar(R) Brake Parts Cleaner or an equivalent. 8. Remove the two nuts (3) attaching the master cylinder (2) to the power brake booster (1). 9. Slide the master cylinder straight out of the power brake booster. 10. To remove the proportioning valves, unthread each from the master cylinder. With ABS WITH ABS NOTE: The master cylinder must be bled before installing it on the vehicle. 1. Bench bleed the master cylinder. See: Procedures 2. Wipe the face of the power brake booster clean where the vacuum seal on the rear of the master cylinder comes in contact when it's installed. Do not get any cleaner or debris inside the booster. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4422 CAUTION: When installing a master cylinder on the vehicle, a NEW vacuum seal (2) MUST be installed on the master cylinder mounting flange (1). 3. If the master cylinder does not have a new vacuum seal (2) on the mounting flange (1), remove it. Install a NEW vacuum seal on the master cylinder mounting flange making sure the seal fits squarely in its groove. CAUTION: If resistance is met during master cylinder insertion into power brake booster, the master cylinder push rod may not be lined up with the booster push rod. Remove the master cylinder, realign and insert it again. 4. Line the master cylinder mounting holes up with the mounting studs on the power brake booster. Ensure the master cylinder piston push rod lines up with the booster push rod, then carefully slide the master cylinder into the power brake booster until it contacts the face of the booster. 5. Install two NEW master cylinder mounting nuts (3). Tighten each nut to 25 Nm (18 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4423 6. If equipped with a manual transaxle and a new reservoir is being installed, using an appropriate cutting tool, cut the clutch actuator port at the center of the "V" groove (2) opening the hydraulic clutch port (1). Discard the severed plug (3). 7. If equipped with a manual transaxle, slide the clutch actuator hose (2) onto the reservoir port (1). Install the hose clamp just past the upset bead on the port. 8. Connect the primary (1) and secondary (2) brake tubes to the master cylinder outlet ports. Tighten the tube nuts to 17 Nm (150 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4424 9. Connect the wiring harness connector (1) to the brake fluid level switch (2). WARNING: A reservoir blocker must be installed on the master cylinder brake fluid reservoir. Failure to install the reservoir blocker can result in fire in the event of an accident, resulting in serious or fatal injury. 10. If not present, a reservoir blocker (1) must be installed on the fluid reservoir (2). The blocker can be removed from the original reservoir by releasing the retaining tab (3) and opening the blocker. To install the blocker, encircle the reservoir neck with the blocker, close the blocker, snapping the retaining tab into place. Make sure the blocker is securely latched. 11. Connect the negative (ground) cable on the battery. 12. Fill the master cylinder reservoir to the proper level. See: Brake Fluid/Service and Repair WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle. If a firm brake pedal cannot be achieved, bleed the brake hydraulic system and check for leaks. See: Brake Bleeding/Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4425 13. Road test the vehicle to ensure proper operation of the brakes. Without ABS WITHOUT ABS NOTE: The proportioning valves are not identical and cannot be interchanged. The proportioning valve that threads into the primary port (3) has M10 x 1 threads going into the master cylinder (1). The proportioning valve that threads into the secondary port (2) has M12 x 1 threads going into the master cylinder (1). 1. If removed, install the proportioning valves (2, 3) in their master cylinder ports. Tighten the proportioning valves to 30 Nm (22 ft. lbs.). NOTE: The master cylinder must be bled before installing it on the vehicle. 2. Bench bleed the master cylinder. See: Procedures 3. Wipe the face of the power brake booster clean where the master cylinder seal comes in contact when it's installed. Do not get any cleaner or debris inside the booster. CAUTION: When installing a master cylinder on the vehicle, a NEW vacuum seal (2) MUST be installed on the master cylinder mounting flange (1). 4. If the master cylinder does not have a new vacuum seal (2) on the mounting flange (1), remove it. Install a NEW vacuum seal on the master cylinder mounting flange making sure the seal fits squarely in its groove. CAUTION: If resistance is met during master cylinder insertion into power brake booster, the master cylinder push rod may not be lined up with the booster push rod. Remove the master cylinder, realign and insert it again. 5. Line the master cylinder mounting holes up with the mounting studs on the power brake booster. Ensure the master cylinder piston push rod lines Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4426 up with the booster push rod, then carefully slide the master cylinder into the power brake booster until it contacts the face of the booster. 6. Install two NEW master cylinder mounting nuts (3). Tighten each nut to 25 Nm (18 ft. lbs.). 7. If equipped with a manual transaxle and a new reservoir is being installed, using an appropriate cutting tool, cut the clutch actuator port at the center of the "V" groove (2) opening the hydraulic clutch port (1). Discard the severed plug (3). 8. If equipped with a manual transaxle, slide the clutch actuator hose (2) onto the reservoir port (1). Install the hose clamp just past the upset bead on the port. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4427 9. Connect the two rear brake tubes (1, 2) to the proportioning valves on the master cylinder (3). Tighten the tube nuts to 17 Nm (150 in. lbs.). 10. Connect the two front brake tubes (1, 2) to the master cylinder. Tighten the tube nuts to 17 Nm (150 in. lbs.). 11. Connect the wiring harness connector (1) to the brake fluid level switch (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4428 WARNING: A reservoir blocker must be installed on the master cylinder brake fluid reservoir. Failure to install the reservoir blocker can result in fire in the event of an accident, resulting in serious or fatal injury. 12. If not present, a reservoir blocker (1) must be installed on the fluid reservoir (2). The blocker can be removed from the original reservoir by releasing the retaining tab (3) and opening the blocker. To install the blocker, encircle the reservoir neck with the blocker, close the blocker, snapping the retaining tab into place. Make sure the blocker is securely latched. 13. Connect the negative (ground) cable on the battery. 14. Fill the master cylinder reservoir to the proper level. See: Brake Fluid/Service and Repair WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle. If a firm brake pedal cannot be achieved, bleed the brake hydraulic system and check for leaks. See: Brake Bleeding/Service and Repair 15. Road test the vehicle to ensure proper operation of the brakes. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4429 Brake Master Cylinder: Overhaul Brake Master Cylinder - Disassembly DISASSEMBLY 1. Clean the master cylinder housing and brake fluid reservoir. Use only Mopar(R) Brake Parts Cleaner or equivalent. 2. Remove the brake fluid reservoir cap (1). Using a syringe or equivalent type tool, empty as much brake fluid as possible from the reservoir. CAUTION: When removing the fluid reservoir (1) from the master cylinder, do not attempt to pry it off using any type of tool. This can damage the fluid reservoir or master cylinder housing. 3. Remove the screw (3) fastening the fluid reservoir (1) to the master cylinder housing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4430 4. Pull the reservoir (1) straight up and remove it from the grommet seals in master cylinder housing (2). 5. If the reservoir is being replaced, remove the fluid level switch. Push together the retaining tabs (1) holding the brake fluid level switch in place in the brake fluid reservoir (2), then pull the brake fluid level switch out the opposite side of the reservoir. 6. Remove the vacuum seal (2) from the master cylinder mounting flange (1). Brake Master Cylinder - Assembly ASSEMBLY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4431 1. Install a NEW vacuum seal (2) on the master cylinder mounting flange (1) making sure the seal fits squarely in its groove. 2. If the reservoir is being replaced, align the brake fluid level switch with its mounting hole on the left side of the master cylinder brake fluid reservoir. Push the switch into the fluid reservoir until the switch retaining tabs (1) are expanded on the other side of the reservoir (2), locking it in place. 3. Lubricate the reservoir mounting area with fresh clean brake fluid. Place the reservoir (1) in position over the grommet seals in the master cylinder (2). Slide the reservoir into the grommet seals by firmly pressing down on the fluid reservoir. Once installed, make sure fluid reservoir is touching the top of both grommet seals. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4432 4. Install the fluid reservoir mounting screw (3). Tighten the screw to 5.5 Nm (48 in. lbs.). 5. Thoroughly bleed the master cylinder before installing it. See: Procedures 6. Install the master cylinder. See: Removal and Replacement/Brake Master Cylinder - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Procedures Wheel Cylinder: Procedures INSPECTION With the brake drum removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders must be replaced. If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake shoes must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 4437 Wheel Cylinder: Removal and Replacement Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Using a brake pedal holder, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir. 2. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 3. Remove the wheel mounting nuts (3), then the tire and wheel assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 4438 4. Access and remove the drum brake shoes (6) from the support plate (2). See: Drum Brake System/Brake Shoe/Service and Repair/Removal and Replacement/Removal 5. Disconnect the brake tube (2) at the wheel cylinder. 6. Remove the wheel cylinder attaching screws (1). 7. Remove the wheel cylinder from the support plate. Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 4439 1. Install the wheel cylinder onto the brake support plate. Install and tighten the mounting screws (1) to 13 Nm (115 in. lbs.). 2. Hand start the brake tube nut (2) into the wheel cylinder (1). Tighten the tube nut to 17 Nm (150 in. lbs.). NOTE: Inspect the brake shoes before installation. See: Drum Brake System/Brake Shoe/Service and Repair/Procedures/Inspection 3. Install the drum brake shoes (6) and drum. Adjust shoes as necessary. See: Drum Brake System/Brake Shoe/Service and Repair/Removal and Replacement/Installation 4. Install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 5. Slowly rotate the rear wheel and verify that the brake drum lightly drags on the shoes. 6. Lower the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Procedures > Page 4440 7. Remove the brake pedal holder. 8. Bleed the wheel cylinder as necessary. See: Brake Bleeding/Service and Repair 9. Road test the vehicle to make sure the brakes operate correctly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal Parking Brake Cable: Service and Repair Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . NOTE: The procedure below applies to either of the two rear parking brake cables. 1. Disconnect and isolate the battery negative cable from its post on the battery. 2. Block the tire and wheel assemblies so the vehicle does not move once the vehicle parking brake lever is released. 3. Remove the center console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal 4. Release and lower the parking brake lever (5). 5. Loosen the adjusting nut on the lever's output cable taking tension off parking brake cables. 6. Remove the parking brake cables (3) from the parking brake cable equalizer (2). 7. Remove the rear seat cushion. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 4446 8. Fold the rear carpeting forward (1) to expose the parking brake cables (4) at the end of the rear floor. 9. Install the box end of a 1/2 inch (13 mm) wrench (2) over the retainer for either the right (3) or left (5) parking brake cable. Push the wrench onto the retainer until the retainer fingers are collapsed. From under the carpeting, grasp the parking brake cable housing and pull the cable straight out of the bracket attached to the floor. 10. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 11. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly (1). 12. Access and remove the parking brake shoes. See: Parking Brake Shoe/Service and Repair/Removal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 4447 13. Remove the hair pin (1) securing the parking brake cable (2) to the brake support plate (3). 14. Pull the parking brake cable from the support plate and hole in trailing link. 15. Remove the screw (4) securing the cable routing clamp (3) to the body (2). 16. Remove the nut (5) securing the cable routing clamp (3) to the fuel tank strap (7). 17. Remove the parking brake cable (1 - right cable, 9 - left cable) with sealing grommet (6) through the hole (8) in the floor pan of the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 4448 Parking Brake Cable: Service and Repair Installation INSTALLATION NOTE: The following procedure applies to either of the two rear parking brake cables. 1. From underneath, push the parking brake cable through the hole (8) in the floor pan of the vehicle making sure the cable sealing grommet (6) is installed in the floor pan as far as possible (without going all the way through) to ensure a good seal. 2. Position the cable routing clamp (3) over the stud on the fuel tank strap (7) and install the nut (5). 3. Position the cable routing clamp (3) and install the screw (4) securing the cable (1 - right cable, 9 - left cable) to the body (2). 4. Insert the parking brake cable through the hole in the trailing link and the support plate (3). 5. Install the hair pin (1) securing the parking brake cable (2) to the brake support plate (3). 6. Install the parking brake shoes (and check adjustment) and components removed to access them. See: Parking Brake Shoe/Service and Repair/Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 4449 7. Install tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 8. Lower the vehicle. 9. Block the tire and wheel assemblies so the vehicle does not move with the vehicle parking brake lever released. 10. Ensure that the seal grommet on the cable installed from underneath is fully seated into the floor pan. 11. Route the parking brake cable under the carpeting, up to the parking brake cable retaining bracket (4) on the floor pan. Insert the parking brake cable (3) through the retaining bracket. Push the cable in until the locking fingers on the cable retainer lock the cable into place. CAUTION: A NEW parking brake cable equalizer (2) must be installed when servicing the parking brake cables or lever. The equalizer has an integrated bent nail tensioner that needs to be stretched upon installation placing the correct tension on the cables. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 4450 12. Remove and install a NEW parking brake cable equalizer (2) on the parking brake lever output cable. 13. Install the rear parking brake cables (3) into the equalizer (2) on the parking brake lever output cable. 14. Ensure that the parking brake cables are correctly installed on the equalizer and aligned with the cable track on the parking brake lever. NOTE: Actuating the parking brake lever to its fully applied position one time after tightening the adjustment nut will yield (stretch) the bent nail portion of the equalizer approximately 1/4 inch. This process will correctly set the parking brake cable tension. 15. Adjust parking brake cable tension using the following steps: a. Place the parking brake lever in the fully released (down) position. b. Tighten the adjusting nut (3) on the parking brake lever output cable until 31 millimeters of thread is out past the end of the adjustment nut (1). c. Actuate the parking brake lever to its fully applied position one time, then reposition it to its fully released (down) position. 16. Raise the vehicle to a point where the rear wheels just clear the floor. 17. Check the rear wheels of the vehicle; they should rotate freely without dragging. 18. Apply the parking brake. Check the rear wheels of the vehicle. They should not rotate. 19. Return the parking brake lever to its fully released (down) position and check the rear wheels. They should rotate freely without dragging. 20. Apply the parking brake. 21. Lower the vehicle. 22. Install the center console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation 23. Remove the blocks from the tires and wheel assemblies. 24. Connect the battery negative cable to its post on the battery. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal Parking Brake Lever: Service and Repair Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . NOTE: The procedure below applies to either of the two rear parking brake cables. 1. Disconnect and isolate the battery negative cable from its post on the battery. 2. Block the tire and wheel assemblies so the vehicle does not move once the vehicle parking brake lever is released. 3. Remove the center console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal 4. Release and lower the parking brake lever (5). 5. Loosen the adjusting nut on the lever's output cable taking tension off parking brake cables. Back the nut off until it is flush with the end of the output cable. 6. Remove the parking brake cables (3) from the parking brake cable equalizer (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal > Page 4455 7. Disconnect the wiring harness connector (2) from the parking brake switch (3). 8. Remove the nuts (1) attaching the parking brake lever (6) to the vehicle. 9. Remove the parking brake lever (6). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal > Page 4456 Parking Brake Lever: Service and Repair Installation INSTALLATION 1. Place the parking brake lever (6) on the mounting studs (5) affixed to the vehicle floor pan. Install and tighten the nuts to 28 Nm (250 in. lbs.). 2. Connect the wiring harness connector (2) to the parking brake switch (3). CAUTION: A NEW parking brake cable equalizer (2) must be installed when servicing the parking brake cables or lever. The equalizer has an Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Removal > Page 4457 integrated bent nail tensioner that needs to be stretched upon installation placing the correct tension on the cables. 3. Remove and install a NEW parking brake cable equalizer (2) on the parking brake lever output cable. 4. Install the rear parking brake cables (3) into the equalizer (2) on the parking brake lever output cable. 5. Ensure that the parking brake cables are correctly installed on the equalizer and aligned with the cable track on the parking brake lever. NOTE: Actuating the parking brake lever to its fully applied position one time after tightening the adjustment nut will yield (stretch) the bent nail portion of the equalizer approximately 6 mm (1/4 inch). This process will correctly set the parking brake cable tension. 6. Adjust parking brake cable tension using the following steps: a. Place the parking brake lever in the fully released (down) position. b. Tighten the adjusting nut (3) on the parking brake lever output cable until 31 millimeters (1.220 inches) of thread is out past the end of the adjustment nut (1). c. Actuate the parking brake lever to its fully applied position one time, then reposition it to its fully released (down) position. 7. Raise the vehicle to a point where the rear wheels just clear the floor. 8. Check the rear wheels of the vehicle; they should rotate freely without dragging. 9. Apply the parking brake. Check the rear wheels of the vehicle. They should not rotate. 10. Return the parking brake lever to its fully released (down) position and check the rear wheels. They should rotate freely without dragging. 11. Apply the parking brake. 12. Lower the vehicle. 13. Install the center console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Installation 14. Remove the blocks from the tires and wheel assemblies. 15. Connect the battery negative cable to its post on the battery. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments Parking Brake Shoe: Adjustments PARKING BRAKE SHOE ADJUSTMENT NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . NOTE: The parking brake shoes used in the drum-in-hat park brake system do not automatically adjust to compensate for brake shoe lining wear. Therefore, it is necessary to manually adjust the parking brake shoes. 1. Verify the parking brake lever is in the released (down) position. 2. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 3. Remove the wheel mounting nuts (3), then the tire and wheel assembly. 4. Install a couple wheel mounting nuts to hold the brake rotor in place while adjustment of the brake shoes is made. NOTE: To find the adjuster wheel with the drum on position the hole (1) in the front of the rotor drum as follows: - Left side - 7 o'clock. - Right side - 5 o'clock. NOTE: When adjusting the parking brake shoes with the drum-in hat rotor installed, rotating the adjuster wheel (2) upward will loosen the adjustment. Rotating the adjuster wheel (2) downward will tighten the adjustment. 5. Remove the rubber plug from the hole (1) in the front of the rotor. 6. Utilizing the hole (1) in the front of the rotor, make a fine adjustment of the shoes. 7. Reinstall the rubber plug. 8. Lower the vehicle far enough to access the interior of the vehicle. 9. Reach inside the vehicle and cycle (fully apply and release) the park brakes. 10. With the parking brake lever in the fully applied (up) position, attempt to hand rotate each rear brake rotor to ensure that the parking brake shoes Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 4461 are working properly. 11. With the parking brake lever in the released (down) position, hand rotate each rear brake rotor to ensure that the parking brake shoes are not dragging. 12. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 13. Remove the wheel mounting nuts and install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 14. Lower the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal Parking Brake Shoe: Service and Repair Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair NOTE: If removing parking brake shoes on both sides of vehicle, perform remaining steps on each side of the vehicle. 2. Access and remove the rear brake rotor (3). See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 3. Turn the brake shoe adjuster wheel until the adjuster is at shortest length. 4. Remove the upper return spring (1) from the anchor pin (3) and the rear brake shoe. 5. Remove the upper return spring (2) from the anchor pin (3) and the front brake shoe. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4464 6. Remove the brake shoe hold-down springs and pins (1, 2). Rotate the pins 90° to disengage. 7. Remove the parking brake cable from the lever on the rear parking brake shoe. 8. Remove the brake shoes (2, 6), adjuster (5) and lower return spring (3) as an assembly from the support plate. 9. If necessary, remove the strut (1). 10. Remove the lower return spring (3) and adjuster (5) from the shoes (2, 6). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4465 Parking Brake Shoe: Service and Repair Installation INSTALLATION NOTE: If replacing parking brake shoes on both sides of vehicle, perform 1 through 15 on each side of the vehicle to complete shoe set installation, then proceed to 16. NOTE: Left side shoes are shown in the figure. Right side shoes are a mirror image of the left except for the adjuster. The threaded portion of the adjuster should always be positioned to the left side in order to maintain consistent side-to-side rotational direction for adjustment purposes. 1. Install the lower return spring (3) and adjuster (5) between the parking brake shoes (2, 6). The rear shoe will have the lever mounted on the inside. Make sure the threaded portion of the adjuster is mounted to the left on both right and left side parking brake assemblies (see preceding note). 2. If necessary, place the strut (1) above the hub and bearing on the vehicle. Note the curved end of the strut (1) is positioned to the rear. 3. Install the assembled brake shoes (2, 6), adjuster (5) and lower return spring (3) over the hub and bearing and onto the support plate and anchor. Be sure to install the strut between the front shoe and the lever on the rear shoe. 4. Install the parking brake cable onto the lever on the parking brake shoe. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4466 5. Install the brake shoe hold-down springs and pins (1, 2). Rotate the pins 90° to engage. 6. Install the front upper return spring (2) holding the front brake shoe and anchor pin (3). 7. Install the rear upper return spring (2) holding the rear brake shoe and anchor pin (3). 8. Using Brake Shoe Gauge C-3919, or equivalent, measure the inside diameter of parking brake drum portion of rotor. Set the Gauge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4467 9. Place Gauge (2) over the parking brake shoes (1) at their widest point. 10. Using the adjuster wheel, adjust the parking brake shoes until the linings on both parking brake shoes just touch the jaws on the Gauge. 11. Install the rear brake rotor (3) and install a couple wheel mounting nuts to hold it in place while a final adjustment is made. NOTE: To find the adjuster wheel with the drum on position the hole (1) in the front of the rotor drum as follows: - Left side - 7 o'clock. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 4468 - Right side - 5 o'clock. NOTE: When adjusting the parking brake shoes with the drum-in hat rotor installed, rotating the adjuster wheel (2) upward will loosen the adjustment. Rotating the adjuster wheel (2) downward will tighten the adjustment. 12. Remove the rubber plug from the hole (1) in the front of the rotor. 13. Utilizing the hole (1) in the front of the rotor, make a final adjustment of the shoes if necessary. 14. Reinstall the rubber plug. 15. Remove the wheel mounting nuts and finish installing the brake rotor (3) as well as all components removed to access it. See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation 16. Lower the vehicle. 17. Cycle the parking brake lever once, verifying proper operation of the parking brake. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4472 Parking Brake Warning Switch: Diagrams Connector - (INSTRUMENT PANEL) 1 WAY SWITCH-PARKING BRAKE - (INSTRUMENT PANEL) 1 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation Vacuum Brake Booster: Description and Operation DESCRIPTION The power brake booster (3) is mounted to the engine side of the dash panel. The master cylinder is bolted to the front of the booster. A vacuum check valve is also mounted on the front of the booster. A vacuum line connects the check valve to engine source vacuum. The booster input rod extends through the dash panel and connects to the brake pedal. This vehicle uses a 254 mm single diaphragm power brake booster. Power brake boosters are internally tuned differently depending on whether the vehicle is equipped with ABS or without ABS. If the power brake booster requires replacement, be sure it is replaced with the correct part. The power brake booster can be identified by the tag attached to the body of the booster. This tag contains the following information: - The production part number - The date it was built, and - The booster manufacturer. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 4477 Vacuum Brake Booster: Testing and Inspection POWER BRAKE BOOSTER BASIC TEST 1. With engine off, depress and release the brake pedal several times to purge all vacuum from the power brake booster. 2. Depress and hold the pedal with light effort (15 to 25 lbs. (6.8 to 11.3 kg) pressure), then start the engine. The pedal should fall slightly, then hold. Less effort should be needed to apply the pedal at this time. If the pedal fell as indicated, perform the VACUUM LEAK TEST listed after the BASIC TEST. If the pedal did not fall, continue on with this BASIC TEST. 3. Disconnect the vacuum hose at the vacuum check and tee-in a vacuum gauge. 4. Start the engine. 5. When the engine is at warm operating temperature, allow it to idle and check the vacuum at the gauge. If the vacuum supply is 12 inches Hg (40.5 kPa) or more, the power brake booster is defective and must be replaced. If the vacuum supply is below 12 inches Hg, continue on with this BASIC TEST. 6. Shut off the engine. 7. Connect the vacuum gauge to the vacuum reference port on the engine intake manifold. 8. Start the engine and observe the vacuum gauge. If the vacuum is still low, check the engine tune and repair as necessary. If the vacuum is above 12 inches, the hose or check to the booster has a restriction or leak. Once an adequate vacuum supply is obtained, repeat the BASIC TEST. VACUUM LEAK TEST 1. Disconnect the vacuum hose at the vacuum check and tee-in a vacuum gauge. 2. Start the engine. 3. Allow the engine to warm up to normal operating temperature and engine idle. 4. Using vacuum line pliers, close off the vacuum supply hose near the booster and observe the vacuum gauge. If the vacuum drop exceeds 1.0 inch Hg (3.3 kPa) in one minute, repeat the above steps to confirm the reading. The vacuum loss should be less than 1.0 inch Hg in one minute time span. If the loss is more than 1.0 inch Hg, replace the power brake booster. If it is not, continue on with this test. 5. Remove the pliers from the hose temporarily. 6. Apply light effort (approximately 15 lbs. (6.8 kg) of force) to the brake pedal and hold the pedal steady. Do not move the pedal once the pressure is applied or the test results may vary. 7. Have an assistant reattach the pliers to the vacuum supply hose. 8. Allow 5 seconds for stabilization, then observe the vacuum gauge. If the vacuum drop exceeds 3.0 inches Hg (10 kPa) in 15 seconds, repeat the above steps to confirm the reading. The vacuum loss should be less than 3.0 inches Hg in 15 seconds time span. If the loss is more than 3.0 inches Hg, replace the power brake booster. If it is not, the booster is not defective. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal Vacuum Brake Booster: Service and Repair Power Brake Booster - Removal LEFT-HAND DRIVE NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Disconnect and isolate the battery negative cable from its post on the battery. 2. Remove the master cylinder. See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Brake Master Cylinder - Removal 3. Disconnect the vacuum hose (2) from the check valve (1) on the power brake booster. Do not remove the check valve from power brake booster. 4. Remove the steering column opening cover (and airbag if equipped) on the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal 5. Remove the mounting screws (2) and reinforcement (1) behind the steering column opening cover. 6. Remove the stop lamp switch See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Removal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 4480 7. Remove the retaining clip (2) securing the power brake booster push rod (1) to the brake pedal. To do so, position a small screwdriver under the center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang to pass over the end of the brake pedal pin (3). Remove and discard the clip. Do not reuse the clip. 8. Slide the booster push rod (1) off the brake pedal pin (3). 9. Remove the four nuts (4) attaching the power brake booster (3) to the dash panel. 10. Slide the power brake booster (3) forward until its mounting studs clear the dash panel, then remove it through the engine compartment. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 4481 Vacuum Brake Booster: Service and Repair Power Brake Booster - Installation LEFT-HAND DRIVE NOTE: Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on the booster mounting studs. 1. Install the power brake booster (3) by sliding the push rod and studs through the dash panel and into mounting position. 2. Under the instrument panel, install the four power brake booster mounting nuts (4). To tighten the nuts, refer to the following step. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 4482 CAUTION: Because of power brake booster design, it is very important to tighten the mounting nuts in the proper sequence. 3. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 Nm (17 ft. lbs.). 4. Using Mopar(R) Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it contacts the brake booster input rod (1). 5. Install the power brake booster push rod (1) on the pin (3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of the pin. Do not reuse the old clip. 6. Install and adjust the stop lamp switch in the brake pedal bracket See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Installation 7. Install the steering column opening cover reinforcement (1) in the steering column opening. Install the mounting screws (2). 8. Install the steering column opening cover (and airbag if equipped) on the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 4483 CAUTION: When installing the vacuum hose on the check valve (1), make sure the hose is routed properly to avoid possible contact with unfriendly surfaces. 9. Connect the vacuum hose (2) to the vacuum check valve (1). 10. Install the master cylinder. See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Brake Master Cylinder Installation 11. Connect the battery negative cable to its post on the battery. 12. Bleed the base brake system if necessary. See: Brake Bleeding/Service and Repair WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle. 13. Road test the vehicle to ensure proper operation of the brakes. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4488 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4489 Electronic Brake Control Module: Diagrams Connector - (ENGINE COMPARTMENT) 47 WAY MODULE-ANTI-LOCK BRAKES - (ENGINE COMPARTMENT) 47 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4490 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module Description Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Description DESCRIPTION The Antilock Brake Module (ABM) is a microprocessor-based device which monitors the antilock brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop or when in a traction control or Electronic Stability Program (ESP) situation. The ABM utilizes a 47-way electrical connector on the vehicle wiring harness. The power source for the ABM is through the ignition switch in the RUN or ON position. The ABM (1) is mounted to the HCU (2) as part of the Integrated Control Unit (ICU). The ICU is located in the engine compartment on the inboard side of the right body frame rail behind the strut tower. For information on the ICU, See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Description and Operation/Integrated Control Unit (ICU) Description - DESCRIPTION). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module Description > Page 4493 Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Operation OPERATION The primary functions of the Antilock Brake Module (ABM) are to: - Monitor the Antilock Brake System (ABS) and Electronic Stability Program (ESP) for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in ABS or traction control mode. - Modulates fluid pressure to the wheel brakes to control vehicle yaw rate in ESP mode. - Store diagnostic information. - Provide communication to the scan tool while in diagnostic mode. - Illuminate the amber ABS indicator in the instrument cluster. - Illuminate the yellow ESP/BAS indicator in the instrument cluster (if equipped). The ABM constantly monitors the ABS and ESP (if equipped) for proper operation. If the ABM detects a fault, it will turn on the amber ABS and yellow ESP/BAS indicators and disable the ABS or ESP if so equipped. The normal base braking system will remain operational at that time. The ABM continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the ABM commands the ABM solenoid coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The ABM continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4498 Brake Fluid Level Sensor/Switch: Diagrams Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-BRAKE FLUID LEVEL - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4499 Brake Fluid Level Sensor/Switch: Description and Operation DESCRIPTION The brake fluid level switch (2) is mounted through the center of the fluid reservoir (1). The switch can be serviced separately from the master cylinder fluid reservoir. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Brake Fluid Level Switch - Removal Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Switch - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Remove the wiring harness connector (1) from the brake fluid level switch (2) in the master cylinder brake fluid reservoir. 2. Push together the retaining tabs (1) holding the brake fluid level switch in place in the brake fluid reservoir (2). 3. Pull the brake fluid level switch out the right side of the reservoir. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Service and Repair > Brake Fluid Level Switch - Removal > Page 4502 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Switch - Installation INSTALLATION 1. Align the brake fluid level switch with its mounting hole on the right side of the master cylinder brake fluid reservoir. Push the switch into the fluid reservoir until the switch retaining tabs (1) are expanded on the opposite side of the reservoir (2), locking it in place. 2. Connect the wiring harness connector (1) to the switch (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 4506 Lateral Accelerometer: Diagrams Connector (ESP) - (BODY) 6 WAY SENSOR-DYNAMICS (ESP) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations > Page 4507 Lateral Accelerometer: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (2). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal Lateral Accelerometer: Service and Repair Dynamics Sensor - Removal REMOVAL NOTE: The Occupancy Restraint Module (ORC) (4) is directly behind the vehicle dynamics sensor (2). Care must be taken while working near the ORC to avoid jostling or bumping the module. 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the shifter housing. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Housing - Removal 3. Position the carpeting out of the way so that the dynamics sensor is accessible. 4. Remove the two nuts (1) mounting the dynamics sensor to the floor pan tunnel. 5. Disconnect the wiring harness connector (3) at the dynamics sensor (2). 6. Remove the dynamics sensor (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 4510 Lateral Accelerometer: Service and Repair Dynamics Sensor - Installation INSTALLATION NOTE: The Occupancy Restraint Module (ORC) (4) is directly behind the vehicle dynamics sensor (2). Care must be taken while working near the ORC to avoid jostling or bumping the module. 1. Connect the wiring harness connector (3) to the dynamics sensor (2). 2. Install the dynamics sensor (2) over the studs mounted to the floor pan tunnel. 3. Install the two mounting nuts (1). Tighten the nuts to 9 Nm (80 in. lbs.). 4. Move carpeting back into original location. 5. Install the shifter housing See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Housing - Installation 6. Connect the battery negative cable to the battery post. It is important that this be performed properly See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection 7. Perform the Verification Test and clear any faults See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4514 Parking Brake Warning Switch: Diagrams Connector - (INSTRUMENT PANEL) 1 WAY SWITCH-PARKING BRAKE - (INSTRUMENT PANEL) 1 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 4518 Steering Angle Sensor: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SENSOR-STEERING ANGLE - (INSTRUMENT PANEL) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Description and Operation Traction Control Switch: Description and Operation DESCRIPTION The ESP Off Switch is part of the accessory switch bank module located in the center bezel on the instrument panel above the transmission gear shifter. The ESP Off switch turns the Electronic Stability Program off whenever the switch is depressed. Depressing the switch a second time turns the ESP(R) back on. The switch resets itself each time the ignition is cycled. When the ESP Off switch is depressed and released, turning ESP(R) off, it does not completely turn the system off. The ESP(R) system reduces torque management to a lesser amount, but ESP(R) function can still occur if the system perceives the need. The ESP Off switch is serviced as part of the accessory switch bank. There are different accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Electronic Stability Program (ESP) Switch - Removal Traction Control Switch: Service and Repair Electronic Stability Program (ESP) Switch - Removal REMOVAL NOTE: The ESP Off switch is integral to the accessory switch bank and cannot be serviced separately. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a work bench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the screws that secure the accessory switch bank to the back of the center bezel and remove the accessory switch bank. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Electronic Stability Program (ESP) Switch - Removal > Page 4524 Traction Control Switch: Service and Repair Electronic Stability Program (ESP) Switch - Installation INSTALLATION NOTE: The ESP Off switch is serviced as part of the accessory switch bank. NOTE: There are different instrument panel accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. 1. Position the accessory switch bank onto the back of the instrument panel center bezel. 2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the center bezel onto the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Reconnect the negative battery cable. 5. Perform the ABS Verification Test and make sure the ESP Off switch operates properly. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test 6. Verify proper operation of all components controlled by the switch bank. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front ABS Wheel Speed Sensor Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front ABS Wheel Speed Sensor > Page 4529 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front ABS Wheel Speed Sensor > Page 4530 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front ABS Wheel Speed Sensor > Page 4531 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way Wheel Speed Sensor: Diagrams Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT FRONT - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 4534 Wheel Speed Sensor: Diagrams Left Front ABS Wheel Speed Sensor (Sensor Side) (Engine Compartment) 2 Way Connector (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT FRONT (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 4535 Wheel Speed Sensor: Diagrams Left Rear ABS Wheel Speed Sensor (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT REAR - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 4536 Wheel Speed Sensor: Diagrams Left Rear ABS Wheel Speed Sensor (Sensor Side) (Body) 2 Way Connector (SENSOR SIDE) - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT REAR (SENSOR SIDE) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 4537 Wheel Speed Sensor: Diagrams Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT FRONT - (ENGINE COMPARTMENT) 2 WAY Left Front ABS Wheel Speed Sensor (Sensor Side) (Engine Compartment) 2 Way Connector (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT FRONT (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 4538 Left Rear ABS Wheel Speed Sensor (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT REAR - (BODY) 2 WAY Left Rear ABS Wheel Speed Sensor (Sensor Side) (Body) 2 Way Connector (SENSOR SIDE) - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT REAR (SENSOR SIDE) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 4539 Right Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT FRONT - (ENGINE COMPARTMENT) 2 WAY Right Front ABS Wheel Speed Sensor (Sensor Side) (Engine Compartment) 2 Way Connector (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT FRONT (SENSOR SIDE) - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 4540 Right Rear ABS Wheel Speed Sensor (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT REAR - (BODY) 2 WAY Right Rear ABS Wheel Speed Sensor (Sensor Side) (Body) 2 Way Connector (SENSOR SIDE) - (BODY) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT REAR (SENSOR SIDE) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front ABS Wheel Speed Sensor (Engine Compartment) 2 Way > Page 4541 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description Wheel Speed Sensor: Description and Operation Wheel Speed Sensor - Description Front DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magneto-resistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. A front wheel speed sensor (3) is attached to a mounting boss on each front knuckle (4). The encoder is an integral part of the hub and bearing. WSS air gaps are not adjustable. Rear DESCRIPTION The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed sensors. The sensors use an electronic principle known as magnetoresistive to help increase performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one encoder. The rear wheel speed sensor head (3) is mounted to the rear of the hub and bearing by a screw. The encoder is integral to the hub and bearing assembly. The encoder is are serviced as part of the rear hub and bearing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description > Page 4544 The WSS air gaps are not adjustable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Wheel Speed Sensor - Description > Page 4545 Wheel Speed Sensor: Description and Operation Wheel Speed Sensor - Operation Front OPERATION The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Rear OPERATION The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels. The ground for the IC and the current sense circuit is provided by the ABM. When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal for each wheel. The resulting signal is interpreted by the ABM as the wheel speed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Removal Front REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Open the hood. 2. Disconnect the wheel speed sensor cable connector (2) from the wiring harness connector (3) on top of the frame rail (1) to the inside of the strut tower. 3. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair 4. Remove the grommet (1) from the hole in the body (7) and pull the wheel speed sensor cable out of the hole. 5. Remove the speed sensor cable routing clip (2) from the outside frame rail (6). 6. Remove the screw fastening the cable routing clamp (3) to the outside frame rail (6). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4548 7. Remove the screw (1) securing the wheel speed sensor routing bracket (2) to the brake flex hose bracket (5). 8. Remove the mounting screw (2) fastening the wheel speed sensor head (3) to the knuckle (4). Pull the sensor head out of the knuckle. NOTE: In the following step, the routing clip can be easily removed without damaging it by rotating it (with entire sensor) counterclockwise. 9. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (4). Remove the sensor from the vehicle. Rear REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4549 NOTE: Before proceeding, See: Service Precautions/Technician Safety Information See: Service Precautions/Vehicle Damage Warnings . 1. Remove the cargo floor cover. 2. Remove the rear floor pan silencer (1). 3. If equipped, remove the nuts mounting the satellite receiver (1) or amplifier (2) to rear floor pan. Move the component aside to allow access to the wheel speed sensor wiring connector through the opening in bottom of the quarter trim panel. 4. Through the opening in the bottom of the quarter trim panel, disconnect the wheel speed sensor cable connector (2) at the body wiring harness connector (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4550 5. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair. 6. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly (1). 7. Remove the grommet (2) from the hole in the body (1) and pull the wheel speed sensor cable out through the hole. 8. Remove the speed sensor cable routing clip (3) from the outside frame rail (4). 9. Remove the screw (1) fastening the cable routing clamp (3) to the rear suspension crossmember (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4551 10. Remove the speed sensor cable routing clip (1) from the trailing link (2). 11. Remove the screw (4) fastening the cable routing clamp to the trailing link. 12. Remove the screw (1) fastening the wheel speed sensor head (3) in the rear of the hub and bearing (2). Remove the sensor from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4552 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Installation Front INSTALLATION CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts or an over extension of cables causing an open circuit. Be sure that cables are installed, routed, and clipped properly. 1. Install the wheel speed sensor head (3) into the knuckle (4). Install the mounting screw (2) and tighten it to 12 Nm (106 in. lbs.). 2. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (4). 3. Position the wheel speed sensor routing bracket (2) on the brake flex hose bracket (5) and install the mounting screw (1). Tighten the mounting screw to 18 Nm (13 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4553 4. Position the wheel speed sensor cable routing clamp (4) on the outside frame rail (6) and install the mounting screw (3). Tighten the mounting screw to 18 Nm (13 ft. lbs.). 5. Install the speed sensor cable routing clip (2) on the outside frame rail (6). 6. Insert the wheel speed sensor cable through the hole in the body (7) and install the grommet (1) in the hole. 7. Lower the vehicle. 8. Connect the wheel speed sensor cable connector (2) to the wiring harness connector (3) on top of the frame rail (1). 9. Perform the Diagnostic Verification Test and clear any faults. See: Brake Bleeding/Service and Repair Rear INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4554 1. Install the wheel speed sensor head (3) into the rear of the hub and bearing (2). 2. Install the wheel speed sensor head mounting screw (1). Tighten the screw to 10 Nm (89 in. lbs.). 3. Position the wheel speed sensor (3) on the trailing link (2) and install the screw (4) securing it in place. Tighten the mounting screw to 18 Nm (13 ft. lbs.). 4. Position the wheel speed sensor (3) and install the routing clip (1) fastening the sensor to the trailing link (2). 5. Position the wheel speed sensor cable routing clamp (3) on the rear suspension crossmember (4) and install the mounting screw (1). Tighten the mounting screw to 18 Nm (13 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4555 6. Install the speed sensor cable routing clip (3) on the outside frame rail (4). NOTE: When inserting the wheel speed sensor cable through the hole in the body, route the cable toward the shock tower to make it easier to grasp the cable to connect it to the body wiring harness connector in a later step. 7. Insert the wheel speed sensor cable (5) through the hole in the body (1) and install the grommet (2) in the hole. 8. Install the tire and wheel assembly (1) See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 4556 10. Through the opening in the bottom of the quarter trim panel, connect the wheel speed sensor cable connector (2) at the body wiring harness connector (3). 11. If equipped, install the satellite receiver (1) or amplifier (2) to rear floor pan. 12. Install the rear floor pan silencer (1). 13. Install the cargo floor cover. 14. Perform the Diagnostic Verification Test and clear any faults. See: Brake Bleeding/Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 4560 Yaw Rate Sensor: Diagrams Connector (ESP) - (BODY) 6 WAY SENSOR-DYNAMICS (ESP) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations > Page 4561 Yaw Rate Sensor: Description and Operation DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (2). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor must be replaced when necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal Yaw Rate Sensor: Service and Repair Dynamics Sensor - Removal REMOVAL NOTE: The Occupancy Restraint Module (ORC) (4) is directly behind the vehicle dynamics sensor (2). Care must be taken while working near the ORC to avoid jostling or bumping the module. 1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the shifter housing. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Housing - Removal 3. Position the carpeting out of the way so that the dynamics sensor is accessible. 4. Remove the two nuts (1) mounting the dynamics sensor to the floor pan tunnel. 5. Disconnect the wiring harness connector (3) at the dynamics sensor (2). 6. Remove the dynamics sensor (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 4564 Yaw Rate Sensor: Service and Repair Dynamics Sensor - Installation INSTALLATION NOTE: The Occupancy Restraint Module (ORC) (4) is directly behind the vehicle dynamics sensor (2). Care must be taken while working near the ORC to avoid jostling or bumping the module. 1. Connect the wiring harness connector (3) to the dynamics sensor (2). 2. Install the dynamics sensor (2) over the studs mounted to the floor pan tunnel. 3. Install the two mounting nuts (1). Tighten the nuts to 9 Nm (80 in. lbs.). 4. Move carpeting back into original location. 5. Install the shifter housing See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Housing - Installation 6. Connect the battery negative cable to the battery post. It is important that this be performed properly See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Reconnection 7. Perform the Verification Test and clear any faults See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Removal REMOVAL WARNING: Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. This will disable the front airbag system. Failure to disconnect the battery could result in accidental front airbag module deployment and possible personal injury.Do not place a non-deployed airbag face down on a hard surface as the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. 1. Remove air cleaner fresh air duct (2) and disconnect and isolate negative battery cable at battery, See: Battery/Service and Repair/Removal and Replacement/Battery - Removal. 2. Remove upper (1) and lower (2) steering column shrouds,See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 4572 3. Remove steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 4. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket integral to the right side of the clockspring (3) on the steering column. 5. Slide the switch away from the clockspring far enough to disengage the slide tab on the bottom of the switch housing from the channel formation in the mounting bracket. Position the multi-function switch (1) aside. 6. Position steering column to the full down position. 7. Position ignition key to the RUN position. 8. Remove screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 9. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and position the SKREEM/WCM (2) back on the lock cylinder housing (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 4573 10. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing. Depress the key cylinder retaining tab. 11. Pull key cylinder (3) and key (2) straight out of the lock cylinder housing as one unit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 4574 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Installation INSTALLATION 1. Place actuator in the lock cylinder housing to the RUN position (if not already there). 2. Insert key into key cylinder and turn key cylinder to the RUN position. 3. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 4. Slide key cylinder into the lock cylinder housing until key cylinder retaining tab locks the cylinder into place. 5. Rotate key back and forth (OFF to START), then remove and reinstall it, making sure key cylinder and lock cylinder housing operate properly. 6. Slide the ring of SKREEM/WCM (2) over lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 7. Install screw (1) fastening the SKREEM/WCM (2) to lock cylinder housing (3). Tighten screw to 2.5 Nm (22 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 4575 8. Install and tighten the screw (2) that secures the mounting tab on the back of the right multi-function switch (1) to the mounting bracket on the clockspring (3). 9. Install steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 10. Install upper (1) and lower (2) steering column shrouds,See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 4576 11. Install air cleaner fresh air duct (2) and disconnect and isolate negative battery cable at battery, See: Battery/Service and Repair/Removal and Replacement/Battery - Installation. 12. Check operation of all steering column mounted components. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 4580 Neutral Safety Switch: Diagrams Connector (MTX) - (BODY) 3 WAY SWITCH-CLUTCH INTERLOCK (MTX) - (BODY) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service and Repair Jump Starting: Service and Repair JUMP STARTING WARNING: Review all safety precautions and warnings in battery/starting/charging sections. Do not jump start a frozen battery, personal injury can result. Do not jump start when maintenance free battery indicator dot is yellow or bright color. Do not jump start a vehicle when the battery fluid is below the top of lead plates. Do not allow jumper cable clamps to touch each other when connected to a booster source. Do not use open flame near battery. Remove metallic jewelry worn on hands or wrists to avoid injury by accidental arcing of battery current. When using a high output boosting device, do not allow battery voltage to exceed 16 volts. Refer to instructions provided with device being used. CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle. TO JUMP START A DISABLED VEHICLE: 1. Raise hood on disabled vehicle and visually inspect engine compartment for: - Battery cable clamp condition, clean if necessary. - Frozen battery. - Yellow or white color test indicator, if equipped. - Generator drive belt condition and tension. - Fuel fumes or leakage, correct if necessary. CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result. 2. When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn off all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF. 3. On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all accessories. 4. Connect jumper cables to booster battery. RED clamp to positive terminal (+) or remote terminal. BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure. 5. On disabled vehicle connect RED jumper cable clamp to positive (+) remote terminal. Connect BLACK jumper cable clamp to engine ground. a. Pull the protective sleeve from the remote positive terminal labeled Position Jump Post Attachment. b. Connect RED jumper cable clamp to positive (+) remote terminal. c. Connect BLACK jumper cable clamp to Negative Jump Post Attachment or engine ground as close to the ground cable attaching point as possible 6. Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery. CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail. 7. Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 minutes), before cranking again. DISCONNECT CABLE CLAMPS AS FOLLOWS: - Disconnect BLACK cable clamp from engine ground on disabled vehicle. - Disconnect RED cable clamp from battery positive remote terminal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Battery Cables - Description Battery Cable: Description and Operation Battery Cables - Description DESCRIPTION The battery cables are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. The battery cables feature a clamping type female battery terminal made of stamped sheet metal that is die cast onto one end of the battery cable wire. A pinch-bolt and nut are installed at the open end of the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then soldered. The battery positive cable wires feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires have a smaller female battery terminal clamp. Both the battery positive and negative cables are available for service replacement only as a unit with the battery wire harness, which may include portions of the wiring circuits for the generator and other components on some vehicles. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Battery Cables - Description > Page 4589 Battery Cable: Description and Operation Battery Cables - Operation OPERATION The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a path back to the battery for electrical current generated by the charging system for restoring the voltage potential of the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The terminal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on the top of the battery. The eyelet terminals secured to the opposite ends of the battery cable wires from the female battery terminal clamps provide secure and reliable connection of the battery cables to the vehicle electrical system. One wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the Totally Integrated Power Module (TIPM), and the other wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the engine starter motor solenoid. The battery negative cable terminal clamp has one wire as an eyelet terminal that connects the battery negative cable to the vehicle powertrain through a ground connection, typically on the engine cylinder block. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 4590 Battery Cable: Testing and Inspection BATTERY CABLES A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cable. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair. When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable. VOLTAGE DROP TEST The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this test, be certain that the following procedures are accomplished: - The battery is fully-charged and load tested. Refer to Standard Procedures for the proper battery charging and load test procedures. - Fully engage the parking brake. - If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park position. If the vehicle is equipped with a manual transmission, place the gearshift selector lever in the Neutral position and block the clutch pedal in the fully depressed position. - Verify that all lamps and accessories are turned off. - To prevent the engine from starting, remove the Automatic Shut Down (ASD) relay. The ASD relay can be found in the Fuse Block located in the left front bumper fascia. See the fuse and relay layout label affixed to the underside of the Fuse Block cover for ASD relay identification and location. 1. Connect the positive lead of the voltmeter (1) to the battery (2) negative terminal post. Connect the negative lead of the voltmeter (1) to the battery (2) negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post. 2. Connect the positive lead of the voltmeter (1) to the battery (2) positive terminal post. Connect the negative lead of the voltmeter (1) to the battery (2) positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 4591 3. Connect the voltmeter (2) to measure between the battery positive cable terminal clamp (1) and the starter solenoid B(+) terminal stud (3). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid B(+) terminal stud. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery positive cable. 4. Connect the voltmeter (1) to measure between the battery (2) negative cable terminal clamp and a good clean ground on the engine block (3). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal Battery Cable: Service and Repair Battery Cables - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Rotate the two retaining clips (3) and remove the air cleaner fresh air duct (2). WARNING: The battery negative and positive cable polarity are different from the gasoline engine equipped vehicles to the diesel engine equipped vehicles. Please note the location of the positive and negative cables prior to service of the battery or related components. NOTE: Diesel battery shown, gasoline battery similar. 3. Remove the nut (2) securing the Totally Integrated Power Module (TIPM) cable (1) to the battery clamp stud (5). 4. Disconnect and isolate the battery negative cable then the positive cable (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 4594 5. Remove the nut (1) securing the negative cable (2) to the body ground stud. 6. Remove the battery cable from the B+ terminal of the generator. 7. Remove the battery cable from the B+ terminal of the starter motor. 8. One at a time, trace the battery cable retaining pushpins, fasteners and routing clips until the cables are free from the vehicle. 9. Remove the battery cables from the engine compartment. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 4595 Battery Cable: Service and Repair Battery Cables - Installation INSTALLATION 1. Position the battery cables in the engine compartment. 2. One at a time, install the battery cable retaining pushpins, fasteners and routing clips until the cables are installed exactly where they were in the vehicle. 3. Connect the battery cable to the B+ terminal of the starter motor. Tighten the cable nut to 13 Nm (115 in. lbs.). 4. Connect the battery cable to the B+ terminal of the generator. Tighten the cable nut to 14 Nm (125 in. lbs.). 5. Install the nut (1) securing the negative cable (2) to the body ground stud. Tighten the cable nut to 12 Nm (9 ft. lbs.). WARNING: The battery negative and positive cable polarity are different from the gasoline engine equipped vehicles to the diesel engine Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Battery Cables - Removal > Page 4596 equipped vehicles. Please note the location of the positive and negative cables prior to service of the battery or related components. NOTE: Diesel battery shown, gasoline battery similar. 6. Connect the battery positive cable then the negative cable (3). 7. Tighten the cable clamp nuts to 5 Nm (45 in. lbs.). 8. Install the nut (2) securing the Totally Integrated Power Module (TIPM) cable (1) to the battery clamp stud (5). 9. Install the air cleaner fresh air duct (2) and secure in place by rotating the two retaining clips (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Description and Operation Battery Tray: Description and Operation DESCRIPTION The battery is placed and secured in a plastic battery tray (3). The battery tray is located in the left front side of the vehicle and is secured in place by one nut (2) and four bolts (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal Battery Tray: Service and Repair Battery Retainer - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Rotate the two retaining clips (3) and remove the air cleaner fresh air duct (2). 3. Remove the battery hold down retaining bolt (1). 4. Remove the battery hold down (2) from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal > Page 4602 Battery Tray: Service and Repair Battery Retainer - Installation INSTALLATION 1. Install the battery hold down (2) into the vehicle. 2. Install the battery hold down retaining bolt (1). Tighten the bolt to 7 Nm (62 in. lbs.). 3. Install the air cleaner fresh air duct (2) and secure in place by rotating the two retaining clips (3). 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal > Page 4603 Battery Tray: Service and Repair Battery Tray - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. On diesel engine equipped vehicles disconnect the vacuum connector (3) and electrical connector (1) from the diesel vacuum valve (2). 3. On diesel engine equipped vehicles lift the diesel vacuum valve bracket (1) up disengaging the mounting tabs from the receptacles (2) in the battery tray. 4. Remove the battery See: Service and Repair/Removal and Replacement/Battery - Removal. 5. Remove the four bolts (1) and one nut (2) securing the battery tray (3) to the left frame rail (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal > Page 4604 6. Lift the battery tray out of the engine compartment and remove from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal > Page 4605 Battery Tray: Service and Repair Battery Tray - Installation INSTALLATION 1. Place the battery tray (3) into the engine compartment over the left frame rail (4). 2. Install the one nut (2) and four bolts (1) securing the battery tray (3) to the frame rail (4). 3. Tighten the nut to 10.5 Nm (93 in. lbs.). 4. Tighten the bolts to 10.5 Nm (93 in. lbs.). 5. Install the battery See: Service and Repair/Removal and Replacement/Battery - Installation. 6. On diesel engine equipped vehicles install the diesel vacuum valve. Push the bracket (1) down until the mounting tabs are completely seated into the receptacles (2) in the battery tray. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Retainer - Removal > Page 4606 7. On diesel engine equipped vehicles connect the vacuum connector (3) and electrical connector (1) to the diesel vacuum valve (2). 8. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications Alternator: Specifications GENERATOR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4611 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Generator 2 Way Alternator: Diagrams Generator 2 Way Connector (GAS) - (POWERTRAIN) 2 WAY GENERATOR (GAS) - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Generator 2 Way > Page 4614 Alternator: Diagrams Generator (Eyelet) (Powertrain) 1 Way Connector (EYELET) - (POWERTRAIN) 1 WAY GENERATOR (EYELET) - (POWERTRAIN) 1 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator - Removal Alternator: Service and Repair Generator - Removal REMOVAL 1. Disconnect and isolate negative battery cable at battery. 2. Remove the right front wheel. 3. Remove the underbody air dam. 4. Remove the accessory drive splash shield. 5. Remove the accessory drive idler pulley. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator - Removal > Page 4617 6. Loosen the lower mounting bolt. 7. Loosen the A/C compressor and relocate, pull down and to outboard side of vehicle to make room to remove generator. 8. Unplug field circuit from generator. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator - Removal > Page 4618 9. Remove the B+ terminal nut and wire. 10. Remove the upper mounting bolt. 11. Remove the generator lower mounting bolt. 12. Relocate the battery terminal (1) to the other side of the A/C line (2) for removal of the generator. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator - Removal > Page 4619 13. Rotate generator pulley down. 14. Slide generator down and out of vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator - Removal > Page 4620 Alternator: Service and Repair Generator - Installation INSTALLATION 1. Move A/C compressor to the side to install generator. 2. Rotate generator and set in place. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator - Removal > Page 4621 Make sure battery terminal (1) is in front of A/C line (2). 3. Loose install lower mounting bolt. 4. Loose install upper mounting bolt. 5. Tighten bolts to GAS 54 Nm (40 ft. lbs.) DIESEL 26 Nm (19 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator - Removal > Page 4622 6. Install the B+ terminal nut and wire and tighten to GAS AND DIESEL 10 Nm (88.5 in. lbs.). 7. Plug in the field circuit to the generator. 8. Install idler pulley and tighten bolt. 9. Install the accessory drive belt. 10. Install splash shield. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator - Removal > Page 4623 11. Install lower air dam. 12. Lower vehicle. 13. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Removal REMOVAL WARNING: Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. This will disable the front airbag system. Failure to disconnect the battery could result in accidental front airbag module deployment and possible personal injury.Do not place a non-deployed airbag face down on a hard surface as the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. 1. Remove air cleaner fresh air duct (2) and disconnect and isolate negative battery cable at battery, See: Battery/Service and Repair/Removal and Replacement/Battery - Removal. 2. Remove upper (1) and lower (2) steering column shrouds,See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 4630 3. Remove steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 4. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket integral to the right side of the clockspring (3) on the steering column. 5. Slide the switch away from the clockspring far enough to disengage the slide tab on the bottom of the switch housing from the channel formation in the mounting bracket. Position the multi-function switch (1) aside. 6. Position steering column to the full down position. 7. Position ignition key to the RUN position. 8. Remove screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 9. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and position the SKREEM/WCM (2) back on the lock cylinder housing (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 4631 10. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing. Depress the key cylinder retaining tab. 11. Pull key cylinder (3) and key (2) straight out of the lock cylinder housing as one unit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 4632 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Installation INSTALLATION 1. Place actuator in the lock cylinder housing to the RUN position (if not already there). 2. Insert key into key cylinder and turn key cylinder to the RUN position. 3. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing. 4. Slide key cylinder into the lock cylinder housing until key cylinder retaining tab locks the cylinder into place. 5. Rotate key back and forth (OFF to START), then remove and reinstall it, making sure key cylinder and lock cylinder housing operate properly. 6. Slide the ring of SKREEM/WCM (2) over lock cylinder housing (3) and engage the retainer fingers in the recesses formed on the lock cylinder housing. 7. Install screw (1) fastening the SKREEM/WCM (2) to lock cylinder housing (3). Tighten screw to 2.5 Nm (22 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 4633 8. Install and tighten the screw (2) that secures the mounting tab on the back of the right multi-function switch (1) to the mounting bracket on the clockspring (3). 9. Install steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 10. Install upper (1) and lower (2) steering column shrouds,See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 4634 11. Install air cleaner fresh air duct (2) and disconnect and isolate negative battery cable at battery, See: Battery/Service and Repair/Removal and Replacement/Battery - Installation. 12. Check operation of all steering column mounted components. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 4638 Neutral Safety Switch: Diagrams Connector (MTX) - (BODY) 3 WAY SWITCH-CLUTCH INTERLOCK (MTX) - (BODY) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications Starter Motor: Specifications STARTER MOTOR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4642 Starter Motor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4643 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Starter (Powertrain) 1 Way Starter Motor: Diagrams Starter (Powertrain) 1 Way Connector - (POWERTRAIN) 1 WAY STARTER - (POWERTRAIN) 1 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Starter (Powertrain) 1 Way > Page 4646 Starter Motor: Diagrams Battery Side Starter Eyelet (Battery) 1 Way Connector - (BATTERY) 1 WAY STARTER-EYELET-BATTERY SIDE - (BATTERY) 1 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Starter (Powertrain) 1 Way > Page 4647 Starter Motor: Diagrams Generator Side Starter Eyelet (Powertrain) 1 Way Connector - (POWERTRAIN) 1 WAY STARTER-EYELET-GENERATOR SIDE - (POWERTRAIN) 1 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter - Removal Starter Motor: Service and Repair Starter - Removal REMOVAL 1. Remove air cleaner box and air tube. 2. Disconnect and isolate the battery negative cable 3. Remove starter motor mounting bolt. 4. Disconnect the electrical connector at throttle body. 5. Remove throttle body bolts and remove throttle body. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter - Removal > Page 4650 6. Push starter under intake manifold. 7. Tip starter nose toward cooling module. 8. Pull starter up and out. 9. Disconnect starter motor wiring. 10. Remove starter motor from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter - Removal > Page 4651 Starter Motor: Service and Repair Starter - Installation INSTALLATION 1. Connect starter motor wiring. Tighten battery cable nut to 10 Nm (90 in. lbs.). 2. Install starter motor into vehicle lower engine compartment. 3. Loose install starter into position. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter - Removal > Page 4652 4. Install throttle body 5. Install throttle body bracket. 6. Install starter motor mounting bolts and tighten to 54 Nm (40 ft. lbs.). 7. Connect throttle body electrical connector. 8. Install air cleaner box and inlet tube. 9. Connect battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet > Page 4658 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4661 It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4662 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4663 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4664 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4665 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4666 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4667 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4671 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4672 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4673 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4674 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4675 Auxiliary Power Outlet: Connector Views AC Power Outlet (Center Console) 6 Way Connector (EXCEPT EXPORT) - (CENTER CONSOLE) 6 WAY POWER OUTLET-AC (EXCEPT EXPORT) - (CENTER CONSOLE) 6 WAY Instrument Panel Power Outlet (Instrument Panel) 3 Way Connector - (INSTRUMENT PANEL) 3 WAY POWER OUTLET-INSTRUMENT PANEL - (INSTRUMENT PANEL) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4676 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Power Outlet - Description Auxiliary Power Outlet: Description and Operation Power Outlet - Description DESCRIPTION INSTRUMENT PANEL MOUNTED An instrument panel mounted cigar lighter/power outlet receptacle is optional equipment on this model. On models equipped with the optional Smoker's Package, the cigar lighter knob and heating element are included. On models without the Smoker's Package, the cigar lighter receptacle is equipped with a snap fit plastic cap and is treated as an auxiliary power outlet. The cigar lighter receptacle is installed in the instrument panel accessory switch bezel, which is located near the bottom of the instrument panel center stack area, below the radio. The cigar lighter base is secured by a snap fit within the center lower bezel. This power outlet has a constant 12 volt battery feed. The cigar lighter receptacle is serviced with the accessory switch bezel and if defective, the entire switch bezel must be replaced. The plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if faulty or damaged, they must be replaced. FRONT CONSOLE AND REAR CARGO MOUNTED A front console mounted power outlet is standard equipment and a rear cargo area power outlet is optional equipment on this model. The front console mounted power outlet is mounted near the front of the console just in front of the cup holders. This outlet can be used as a cigar lighter or power outlet, but only has 12 volt battery voltage when the ignition is in the ON or ACC positions. The rear power outlet is installed in the right rear quarter trim panel, near the spare tire jack (2). The power outlet base and mount are secured by a snap fit within the quarter trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. It has 12 volt battery voltage when the ignition is in the ON or ACC positions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Power Outlet - Description > Page 4679 Auxiliary Power Outlet: Description and Operation Power Outlet - Operation OPERATION CIGAR LIGHTER/POWER OUTLET The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the receptacle shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. POWER OUTLET The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the Totally Integrated Power Module (TIPM) through a fuse in the fuse block when the ignition is in the ON or ACC positions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Power Outlet - Removal Auxiliary Power Outlet: Service and Repair Power Outlet - Removal Power Outlet REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Look inside and note position of the retaining bosses (1). 3. Using special tool 9857 Power Outlet Remover. Insert the tool forcing the bosses out of base. 4. Pull out the base through mounting ring by gently rocking the tool (3). 5. Disconnect the base wires. 6. Set base aside and remove base mount ring. AC Power Outlet REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the center console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal. 3. Disconnect electrical connector. 4. Remove AC power outlet. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Power Outlet - Removal > Page 4682 Auxiliary Power Outlet: Service and Repair Power Outlet - Installation Power Outlet INSTALLATION 1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and the mount ring with the index tab at 9 o'clock to the key in the instrument panel. Install the ring. 2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring at the same location. 3. Push base into the bezel till it locks. 4. Install cigar lighter cap. 5. Connect the battery negative cable. AC Power Outlet INSTALLATION 1. Install the AC power outlet. 2. Connect electrical connector. 3. Install the center console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal. 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations Fuse: Locations SPECIFICATIONS An Integrated Power Module (IPM) is located in the engine compartment near the air cleaner assembly. This center contains cartridge fuses and mini-fuses. A label that identifies each component may be printed on the inside of the cover. Refer to "Engine Compartment" of the Owner's Manual for the underhood location of the IPM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4686 CAUTION: When installing the IPM cover, it is important to ensure the cover is properly positioned and fully latched. Failure to do so may allow water to get into the IPM, and possibly result in an electrical system failure. CAUTION: When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4689 It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4692 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 Fuse: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 4703 Fuse: Application and ID Connector - (IN TIPM) FUSE 10 - (IN TIPM) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 4704 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Description and Operation > IOD Fuse - Description Fuse: Description and Operation IOD Fuse - Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the TIPM as part of the preparation procedures performed just prior to new vehicle delivery. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Description and Operation > IOD Fuse - Description > Page 4707 Fuse: Description and Operation IOD Fuse - Operation OPERATION The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Totally Integrated Power Module (TIPM) fuse cavities 7 and 8 in a preset fuse holder. when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Service and Repair > IOD Fuse - Removal Fuse: Service and Repair IOD Fuse - Removal REMOVAL NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the Off position. Failure to place the ignition switch in the Off position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the Off position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the Off position. 2. Remove the cover from the Totally Integrated Power Module (TIPM). 3. Remove fuse 7/8 from the TIPM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Service and Repair > IOD Fuse - Removal > Page 4710 Fuse: Service and Repair IOD Fuse - Installation INSTALLATION CAUTION: It is extremely important that the Ignition Off Draw (IOD) fuses are fully seated into the Totally Integrated Power Module (TIPM) fuse cavities. Failure to install the fuses correctly could result in erratic electrical systems behavior. 1. Remove TIPM cover. 2. Insert fuse 7/8 into the TIPM. Push fuses down until they are fully seated in the TIPM cavities. 3. Install the cover to the TIPM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 4714 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4717 It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4718 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4719 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4720 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4721 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4722 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4723 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4724 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4725 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4726 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4727 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4728 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4729 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4730 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4731 Fuse Block: Application and ID Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4732 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Fuse Block - Description Fuse Block: Description and Operation Fuse Block - Description DESCRIPTION An electrical Fuse Block is located in the left front bumper fascia. It serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. There are two clips that retain the fuse block cover to the fuse block. The cover can be removed to service the fuses and relays by depressing the clips and lifting off the cover. If fuse block wire terminal or insulator service is required the complete fuse block assembly must be removed, See: Service and Repair/Fuse Block - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Fuse Block - Description > Page 4735 Fuse Block: Description and Operation Fuse Block - Operation OPERATION The fuse block houses relays and blade-type fuses. The fuses, relays and fuse block unit are available for service replacement. Refer to Wiring Diagrams for complete circuit diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block - Removal Fuse Block: Service and Repair Fuse Block - Removal REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the front bumper fascia. See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Installation. 3. Depress mounting clips and lift the fuse block off the bracket. 4. Remove the wire harness and fuse block. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block - Removal > Page 4738 Fuse Block: Service and Repair Fuse Block - Installation INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Install the new wire harness and fuse block into the vehicle. 2. Position the fuse block onto the mounting bracket and push down until the mounting clips are fully seated. 3. Install the front bumper fascia. See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Removal. 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component Information > Specifications Ground Strap: Specifications SPECIFICATIONS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 Power Distribution Module: Locations Totally Integrated Power Module C1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4746 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4747 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4748 Power Distribution Module: Locations Totally Integrated Power Module C2 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4749 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4750 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4751 Power Distribution Module: Locations Totally Integrated Power Module C3 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4752 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4753 Power Distribution Module: Locations Totally Integrated Power Module C4 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4754 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4755 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4756 Power Distribution Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4757 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4758 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4759 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4760 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4761 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4762 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4763 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4764 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4765 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4766 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4767 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4768 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4769 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4770 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4771 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4772 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4773 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4774 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4775 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4776 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4777 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4778 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4779 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4780 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4781 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4782 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way Power Distribution Module: Diagrams Inverter Module (Instrument Panel) 9 Way Connector (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4785 Power Distribution Module: Diagrams Totally Integrated Power Module C1 (Engine Compartment) 13 Way Connector C1 - (ENGINE COMPARTMENT) 13 WAY C1 TIPM - (ENGINE COMPARTMENT) 13 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4786 Power Distribution Module: Diagrams Totally Integrated Power Module C2 (Engine Compartment) 14 Way Connector C2 - (ENGINE COMPARTMENT) 14 WAY C2 TIPM - (ENGINE COMPARTMENT) 14 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4787 Power Distribution Module: Diagrams Totally Integrated Power Module C3 (Engine Compartment) 16 Way Connector C3 - (ENGINE COMPARTMENT) 16 WAY C3 TIPM - (ENGINE COMPARTMENT) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4788 Power Distribution Module: Diagrams Inverter Module (Instrument Panel) 9 Way Connector (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY Totally Integrated Power Module C1 (Engine Compartment) 13 Way Connector C1 - (ENGINE COMPARTMENT) 13 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4789 C1 TIPM - (ENGINE COMPARTMENT) 13 WAY Totally Integrated Power Module C2 (Engine Compartment) 14 Way Connector C2 - (ENGINE COMPARTMENT) 14 WAY C2 TIPM - (ENGINE COMPARTMENT) 14 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4790 Totally Integrated Power Module C3 (Engine Compartment) 16 Way Connector C3 - (ENGINE COMPARTMENT) 16 WAY C3 TIPM - (ENGINE COMPARTMENT) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4791 Totally Integrated Power Module C4 (Engine Compartment) 10 Way Connector C4 - (ENGINE COMPARTMENT) 10 WAY C4 TIPM - (ENGINE COMPARTMENT) 10 WAY Totally Integrated Power Module C5 (Engine Compartment) 14 Way Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4792 Connector C5 - (ENGINE COMPARTMENT) 14 WAY C5 TIPM - (ENGINE COMPARTMENT) 14 WAY Totally Integrated Power Module C6 (Engine Compartment) 13 Way Connector C6 - (ENGINE COMPARTMENT) 13 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4793 C6 TIPM - (ENGINE COMPARTMENT) 13 WAY Totally Integrated Power Module C7 (Engine Compartment) 22 Way Connector C7 - (ENGINE COMPARTMENT) 22 WAY C7 TIPM - (ENGINE COMPARTMENT) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4794 Totally Integrated Power Module C8 (Engine Compartment) 22 Way Connector C8 - (ENGINE COMPARTMENT) 22 WAY C8 TIPM - (ENGINE COMPARTMENT) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4795 Totally Integrated Power Module C9 (Battery Feed To TIPM) 1 Way Connector C9 - (BATTERY FEED TO TIPM) 1 WAY C9 TIPM - (BATTERY FEED TO TIPM) 1 WAY Totally Integrated Power Module C10 (Engine Compartment) 8 Way Connector C10 - (ENGINE COMPARTMENT) 8 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4796 C10 TIPM - (ENGINE COMPARTMENT) 8 WAY Totally Integrated Power Module C11 (Engine Compartment) 22 Way Connector C11 - (ENGINE COMPARTMENT) 22 WAY C11 TIPM - (ENGINE COMPARTMENT) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4797 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description Power Distribution Module: Description and Operation Power Inverter Module - Description DESCRIPTION The inverter module is located in the instrument panel. The A/C outlet is mounted in the center console. The inverter module provides A/C power for user accessories. The inverter converts the 12 Volt DC from the battery system to a 110 Volt AC output. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description > Page 4800 Power Distribution Module: Description and Operation Power Inverter Module - Operation OPERATION The AC power outlet receives 12 volts from the Totally Integrated Power Module (TIPM) and passes it as an enable signal to the inverter module. The inverter module also receives 12 volts via the TIPM and inverts this to a 110 volt AC output. The enable signal received from the power outlet enables the inverter to convert the received voltage and pass it to the power outlet to power external devices. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description > Page 4801 Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM) (1). The molded plastic TIPM housing is located in the left front corner of the engine compartment, just behind the air cleaner housing and the battery. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse and relay layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the left inner fender well an indexing pin and one screw. All of the TIPM outputs are through the integral engine compartment wire harness. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description > Page 4802 Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Operation OPERATION All of the current from the generator cable connection goes to the battery through a 10 gauge fusible link that is secured with a nut to the positive battery terminal at the starter. Internal connection of all the Totally Integrated Power Module (TIPM) circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fusible link, fuses and relays are available for service replacement. The TIPM unit cannot be repaired and is only serviced as a unit with the engine compartment wire harness. If the TIPM is inoperative or damaged, the engine compartment wire harness assembly must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Power Distribution Module: Component Tests and General Diagnostics INVERTER MODULE For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 110 VOLT POWER OUTLET DIAGNOSIS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 4805 Power Distribution Module: Programming and Relearning PROGRAMMING 1. Install a battery charger. 2. Verify that the charging rate provides approximately 13.5 volts. NOTE: Do not allow the charger to time out during the reconfiguration process. Set the battery charger timer (if so equipped) to continuous charge. 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 5. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 6. Select "ECU View". 7. Select "TIPMCGW" or "FCMCGW". 8. Select "MISC". 9. Select "Restore Vehicle Configuration". 10. Follow prompts on StarSCAN to complete the reconfigure procedure. 11. Once complete, Wait one minute and turn the ignition key to the "OFF" position. 12. Remove the StarSCAN unit, cable and charger from the vehicle. 13. Verify proper operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal Power Distribution Module: Service and Repair Power Inverter Module - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the shift bezel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Removal 3. Remove the center bezel from the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 4. Remove the fasteners from the mounting brackets of the inverter module. 5. Disconnect the electrical connectors and remove the inverter module. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 4808 Power Distribution Module: Service and Repair Power Inverter Module - Installation INSTALLATION 1. Connect the electrical connectors to the inverter module. 2. Install the fasteners to the mounting brackets. 3. Install the center bezel to the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Install the shift bezel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Installation. 5. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 4809 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) - Removal REMOVAL The TIPM (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. Refer to Wiring Diagrams for more information on the locations of the affected connectors. 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect each of the engine compartment wire harness connectors. 4. Remove the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. 5. Disengage each of the retainers that secure the engine compartment wire harness to the vehicle body and chassis components. 6. Disengage and remove the TIPM housing from its mounting bracket. 7. Remove the TIPM and the engine compartment wire harness from the engine compartment as a unit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 4810 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) Installation INSTALLATION CAUTION: The original Cabin Compartment Node (CCN) and Powertrain Control Module (PCM) must be installed and functioning properly prior to powering up the new Totally Integrated Power Module (TIPM). The TIPM receives vehicle configuration data from the CCN and Vehicle Identification Number (VIN) information from the PCM. If configuration information becomes lost or corrupted, the data can be obtained from DealerCONNECT The Totally Integrated Power Module (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. 1. Position the TIPM in the engine compartment. 2. Align the TIPM on its mounting bracket and install. 3. Route the engine compartment wire harness from the TIPM through the engine compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. Refer to Wiring Diagrams for more information on the harness routing and retainer locations. 4. Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. Refer to Wiring Diagrams for more information on the ground eyelet locations. 5. Reconnect each of the engine compartment wire harness connectors. Refer to Wiring Diagrams for more information on the locations of the affected connectors. 6. Torque nut retaining positive battery cable at TIPM to 96 - 141 Nm (85 - 130 in. lbs.). 7. Reconnect the battery negative cable. 8. Close hood. 9. Verify vehicle and system operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay - Removal Power Distribution Relay: Service and Repair Relay - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay - Removal > Page 4815 Power Distribution Relay: Service and Repair Relay - Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 Power Distribution Module: Locations Totally Integrated Power Module C1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4821 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4822 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4823 Power Distribution Module: Locations Totally Integrated Power Module C2 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4824 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4825 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4826 Power Distribution Module: Locations Totally Integrated Power Module C3 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4827 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4828 Power Distribution Module: Locations Totally Integrated Power Module C4 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4829 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4830 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4831 Power Distribution Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4832 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4833 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4834 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4835 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4836 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4837 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4838 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4839 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4840 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4841 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4842 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4843 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4844 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4845 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4846 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4847 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4848 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4849 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4850 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4851 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4852 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4853 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4854 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4855 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4856 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4857 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way Power Distribution Module: Diagrams Inverter Module (Instrument Panel) 9 Way Connector (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4860 Power Distribution Module: Diagrams Totally Integrated Power Module C1 (Engine Compartment) 13 Way Connector C1 - (ENGINE COMPARTMENT) 13 WAY C1 TIPM - (ENGINE COMPARTMENT) 13 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4861 Power Distribution Module: Diagrams Totally Integrated Power Module C2 (Engine Compartment) 14 Way Connector C2 - (ENGINE COMPARTMENT) 14 WAY C2 TIPM - (ENGINE COMPARTMENT) 14 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4862 Power Distribution Module: Diagrams Totally Integrated Power Module C3 (Engine Compartment) 16 Way Connector C3 - (ENGINE COMPARTMENT) 16 WAY C3 TIPM - (ENGINE COMPARTMENT) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4863 Power Distribution Module: Diagrams Inverter Module (Instrument Panel) 9 Way Connector (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY Totally Integrated Power Module C1 (Engine Compartment) 13 Way Connector C1 - (ENGINE COMPARTMENT) 13 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4864 C1 TIPM - (ENGINE COMPARTMENT) 13 WAY Totally Integrated Power Module C2 (Engine Compartment) 14 Way Connector C2 - (ENGINE COMPARTMENT) 14 WAY C2 TIPM - (ENGINE COMPARTMENT) 14 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4865 Totally Integrated Power Module C3 (Engine Compartment) 16 Way Connector C3 - (ENGINE COMPARTMENT) 16 WAY C3 TIPM - (ENGINE COMPARTMENT) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4866 Totally Integrated Power Module C4 (Engine Compartment) 10 Way Connector C4 - (ENGINE COMPARTMENT) 10 WAY C4 TIPM - (ENGINE COMPARTMENT) 10 WAY Totally Integrated Power Module C5 (Engine Compartment) 14 Way Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4867 Connector C5 - (ENGINE COMPARTMENT) 14 WAY C5 TIPM - (ENGINE COMPARTMENT) 14 WAY Totally Integrated Power Module C6 (Engine Compartment) 13 Way Connector C6 - (ENGINE COMPARTMENT) 13 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4868 C6 TIPM - (ENGINE COMPARTMENT) 13 WAY Totally Integrated Power Module C7 (Engine Compartment) 22 Way Connector C7 - (ENGINE COMPARTMENT) 22 WAY C7 TIPM - (ENGINE COMPARTMENT) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4869 Totally Integrated Power Module C8 (Engine Compartment) 22 Way Connector C8 - (ENGINE COMPARTMENT) 22 WAY C8 TIPM - (ENGINE COMPARTMENT) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4870 Totally Integrated Power Module C9 (Battery Feed To TIPM) 1 Way Connector C9 - (BATTERY FEED TO TIPM) 1 WAY C9 TIPM - (BATTERY FEED TO TIPM) 1 WAY Totally Integrated Power Module C10 (Engine Compartment) 8 Way Connector C10 - (ENGINE COMPARTMENT) 8 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4871 C10 TIPM - (ENGINE COMPARTMENT) 8 WAY Totally Integrated Power Module C11 (Engine Compartment) 22 Way Connector C11 - (ENGINE COMPARTMENT) 22 WAY C11 TIPM - (ENGINE COMPARTMENT) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 4872 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description Power Distribution Module: Description and Operation Power Inverter Module - Description DESCRIPTION The inverter module is located in the instrument panel. The A/C outlet is mounted in the center console. The inverter module provides A/C power for user accessories. The inverter converts the 12 Volt DC from the battery system to a 110 Volt AC output. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description > Page 4875 Power Distribution Module: Description and Operation Power Inverter Module - Operation OPERATION The AC power outlet receives 12 volts from the Totally Integrated Power Module (TIPM) and passes it as an enable signal to the inverter module. The inverter module also receives 12 volts via the TIPM and inverts this to a 110 volt AC output. The enable signal received from the power outlet enables the inverter to convert the received voltage and pass it to the power outlet to power external devices. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description > Page 4876 Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM) (1). The molded plastic TIPM housing is located in the left front corner of the engine compartment, just behind the air cleaner housing and the battery. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse and relay layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the left inner fender well an indexing pin and one screw. All of the TIPM outputs are through the integral engine compartment wire harness. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description > Page 4877 Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Operation OPERATION All of the current from the generator cable connection goes to the battery through a 10 gauge fusible link that is secured with a nut to the positive battery terminal at the starter. Internal connection of all the Totally Integrated Power Module (TIPM) circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fusible link, fuses and relays are available for service replacement. The TIPM unit cannot be repaired and is only serviced as a unit with the engine compartment wire harness. If the TIPM is inoperative or damaged, the engine compartment wire harness assembly must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Power Distribution Module: Component Tests and General Diagnostics INVERTER MODULE For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 110 VOLT POWER OUTLET DIAGNOSIS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 4880 Power Distribution Module: Programming and Relearning PROGRAMMING 1. Install a battery charger. 2. Verify that the charging rate provides approximately 13.5 volts. NOTE: Do not allow the charger to time out during the reconfiguration process. Set the battery charger timer (if so equipped) to continuous charge. 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 5. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 6. Select "ECU View". 7. Select "TIPMCGW" or "FCMCGW". 8. Select "MISC". 9. Select "Restore Vehicle Configuration". 10. Follow prompts on StarSCAN to complete the reconfigure procedure. 11. Once complete, Wait one minute and turn the ignition key to the "OFF" position. 12. Remove the StarSCAN unit, cable and charger from the vehicle. 13. Verify proper operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module Removal Power Distribution Module: Service and Repair Power Inverter Module - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the shift bezel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Removal 3. Remove the center bezel from the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 4. Remove the fasteners from the mounting brackets of the inverter module. 5. Disconnect the electrical connectors and remove the inverter module. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module Removal > Page 4883 Power Distribution Module: Service and Repair Power Inverter Module - Installation INSTALLATION 1. Connect the electrical connectors to the inverter module. 2. Install the fasteners to the mounting brackets. 3. Install the center bezel to the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Install the shift bezel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Installation. 5. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module Removal > Page 4884 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) - Removal REMOVAL The TIPM (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. Refer to Wiring Diagrams for more information on the locations of the affected connectors. 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect each of the engine compartment wire harness connectors. 4. Remove the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. 5. Disengage each of the retainers that secure the engine compartment wire harness to the vehicle body and chassis components. 6. Disengage and remove the TIPM housing from its mounting bracket. 7. Remove the TIPM and the engine compartment wire harness from the engine compartment as a unit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module Removal > Page 4885 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) Installation INSTALLATION CAUTION: The original Cabin Compartment Node (CCN) and Powertrain Control Module (PCM) must be installed and functioning properly prior to powering up the new Totally Integrated Power Module (TIPM). The TIPM receives vehicle configuration data from the CCN and Vehicle Identification Number (VIN) information from the PCM. If configuration information becomes lost or corrupted, the data can be obtained from DealerCONNECT The Totally Integrated Power Module (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. 1. Position the TIPM in the engine compartment. 2. Align the TIPM on its mounting bracket and install. 3. Route the engine compartment wire harness from the TIPM through the engine compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. Refer to Wiring Diagrams for more information on the harness routing and retainer locations. 4. Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. Refer to Wiring Diagrams for more information on the ground eyelet locations. 5. Reconnect each of the engine compartment wire harness connectors. Refer to Wiring Diagrams for more information on the locations of the affected connectors. 6. Torque nut retaining positive battery cable at TIPM to 96 - 141 Nm (85 - 130 in. lbs.). 7. Reconnect the battery negative cable. 8. Close hood. 9. Verify vehicle and system operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay - Removal Power Distribution Relay: Service and Repair Relay - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay - Removal > Page 4890 Power Distribution Relay: Service and Repair Relay - Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4894 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4895 Relay Box: Application and ID Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4899 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4900 Relay Box: Application and ID Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > AC Power Outlet > Page 4906 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4909 It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4910 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4911 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4912 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4913 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4914 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4915 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4916 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4917 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4918 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4919 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4920 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4921 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4922 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4923 Auxiliary Power Outlet: Connector Views AC Power Outlet (Center Console) 6 Way Connector (EXCEPT EXPORT) - (CENTER CONSOLE) 6 WAY POWER OUTLET-AC (EXCEPT EXPORT) - (CENTER CONSOLE) 6 WAY Instrument Panel Power Outlet (Instrument Panel) 3 Way Connector - (INSTRUMENT PANEL) 3 WAY POWER OUTLET-INSTRUMENT PANEL - (INSTRUMENT PANEL) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 4924 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Power Outlet - Description Auxiliary Power Outlet: Description and Operation Power Outlet - Description DESCRIPTION INSTRUMENT PANEL MOUNTED An instrument panel mounted cigar lighter/power outlet receptacle is optional equipment on this model. On models equipped with the optional Smoker's Package, the cigar lighter knob and heating element are included. On models without the Smoker's Package, the cigar lighter receptacle is equipped with a snap fit plastic cap and is treated as an auxiliary power outlet. The cigar lighter receptacle is installed in the instrument panel accessory switch bezel, which is located near the bottom of the instrument panel center stack area, below the radio. The cigar lighter base is secured by a snap fit within the center lower bezel. This power outlet has a constant 12 volt battery feed. The cigar lighter receptacle is serviced with the accessory switch bezel and if defective, the entire switch bezel must be replaced. The plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if faulty or damaged, they must be replaced. FRONT CONSOLE AND REAR CARGO MOUNTED A front console mounted power outlet is standard equipment and a rear cargo area power outlet is optional equipment on this model. The front console mounted power outlet is mounted near the front of the console just in front of the cup holders. This outlet can be used as a cigar lighter or power outlet, but only has 12 volt battery voltage when the ignition is in the ON or ACC positions. The rear power outlet is installed in the right rear quarter trim panel, near the spare tire jack (2). The power outlet base and mount are secured by a snap fit within the quarter trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. It has 12 volt battery voltage when the ignition is in the ON or ACC positions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Power Outlet - Description > Page 4927 Auxiliary Power Outlet: Description and Operation Power Outlet - Operation OPERATION CIGAR LIGHTER/POWER OUTLET The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the receptacle shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. POWER OUTLET The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the Totally Integrated Power Module (TIPM) through a fuse in the fuse block when the ignition is in the ON or ACC positions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Power Outlet - Removal Auxiliary Power Outlet: Service and Repair Power Outlet - Removal Power Outlet REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Look inside and note position of the retaining bosses (1). 3. Using special tool 9857 Power Outlet Remover. Insert the tool forcing the bosses out of base. 4. Pull out the base through mounting ring by gently rocking the tool (3). 5. Disconnect the base wires. 6. Set base aside and remove base mount ring. AC Power Outlet REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the center console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal. 3. Disconnect electrical connector. 4. Remove AC power outlet. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Power Outlet - Removal > Page 4930 Auxiliary Power Outlet: Service and Repair Power Outlet - Installation Power Outlet INSTALLATION 1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and the mount ring with the index tab at 9 o'clock to the key in the instrument panel. Install the ring. 2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring at the same location. 3. Push base into the bezel till it locks. 4. Install cigar lighter cap. 5. Connect the battery negative cable. AC Power Outlet INSTALLATION 1. Install the AC power outlet. 2. Connect electrical connector. 3. Install the center console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal. 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations Fuse: Locations SPECIFICATIONS An Integrated Power Module (IPM) is located in the engine compartment near the air cleaner assembly. This center contains cartridge fuses and mini-fuses. A label that identifies each component may be printed on the inside of the cover. Refer to "Engine Compartment" of the Owner's Manual for the underhood location of the IPM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Page 4934 CAUTION: When installing the IPM cover, it is important to ensure the cover is properly positioned and fully latched. Failure to do so may allow water to get into the IPM, and possibly result in an electrical system failure. CAUTION: When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4937 It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4938 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4939 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4940 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4941 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4942 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4943 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4944 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4945 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4946 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4947 Fuse: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4948 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4949 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4950 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 4951 Fuse: Application and ID Connector - (IN TIPM) FUSE 10 - (IN TIPM) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 4952 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Description and Operation > IOD Fuse - Description Fuse: Description and Operation IOD Fuse - Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the TIPM as part of the preparation procedures performed just prior to new vehicle delivery. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Description and Operation > IOD Fuse - Description > Page 4955 Fuse: Description and Operation IOD Fuse - Operation OPERATION The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position, including the clock. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Totally Integrated Power Module (TIPM) fuse cavities 7 and 8 in a preset fuse holder. when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Service and Repair > IOD Fuse - Removal Fuse: Service and Repair IOD Fuse - Removal REMOVAL NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the Off position. Failure to place the ignition switch in the Off position can cause the radio display to become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with the ignition switch in the Off position will usually correct the scrambled radio display condition. 1. Turn the ignition switch to the Off position. 2. Remove the cover from the Totally Integrated Power Module (TIPM). 3. Remove fuse 7/8 from the TIPM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Service and Repair > IOD Fuse - Removal > Page 4958 Fuse: Service and Repair IOD Fuse - Installation INSTALLATION CAUTION: It is extremely important that the Ignition Off Draw (IOD) fuses are fully seated into the Totally Integrated Power Module (TIPM) fuse cavities. Failure to install the fuses correctly could result in erratic electrical systems behavior. 1. Remove TIPM cover. 2. Insert fuse 7/8 into the TIPM. Push fuses down until they are fully seated in the TIPM cavities. 3. Install the cover to the TIPM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 4962 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4965 It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4966 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4967 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4968 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4969 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4970 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4971 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4972 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4973 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4974 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4975 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4976 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4977 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4978 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4979 Fuse Block: Application and ID Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 4980 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Fuse Block - Description Fuse Block: Description and Operation Fuse Block - Description DESCRIPTION An electrical Fuse Block is located in the left front bumper fascia. It serves to simplify and centralize numerous electrical components, as well as to distribute electrical current to many of the accessory systems in the vehicle. There are two clips that retain the fuse block cover to the fuse block. The cover can be removed to service the fuses and relays by depressing the clips and lifting off the cover. If fuse block wire terminal or insulator service is required the complete fuse block assembly must be removed, See: Service and Repair/Fuse Block - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Fuse Block - Description > Page 4983 Fuse Block: Description and Operation Fuse Block - Operation OPERATION The fuse block houses relays and blade-type fuses. The fuses, relays and fuse block unit are available for service replacement. Refer to Wiring Diagrams for complete circuit diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block - Removal Fuse Block: Service and Repair Fuse Block - Removal REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the front bumper fascia. See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Installation. 3. Depress mounting clips and lift the fuse block off the bracket. 4. Remove the wire harness and fuse block. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Fuse Block - Removal > Page 4986 Fuse Block: Service and Repair Fuse Block - Installation INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Install the new wire harness and fuse block into the vehicle. 2. Position the fuse block onto the mounting bracket and push down until the mounting clips are fully seated. 3. Install the front bumper fascia. See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Removal. 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Specifications Ground Strap: Specifications SPECIFICATIONS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 Power Distribution Module: Locations Totally Integrated Power Module C1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4994 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4995 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4996 Power Distribution Module: Locations Totally Integrated Power Module C2 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4997 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4998 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 4999 Power Distribution Module: Locations Totally Integrated Power Module C3 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5000 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5001 Power Distribution Module: Locations Totally Integrated Power Module C4 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5002 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5003 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5004 Power Distribution Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5005 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5006 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5007 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5008 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5009 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5010 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5011 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5012 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5013 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5014 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5015 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5016 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5017 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5018 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5019 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5020 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5021 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5022 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5023 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5024 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5025 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5026 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5027 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5028 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5029 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5030 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way Power Distribution Module: Diagrams Inverter Module (Instrument Panel) 9 Way Connector (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5033 Power Distribution Module: Diagrams Totally Integrated Power Module C1 (Engine Compartment) 13 Way Connector C1 - (ENGINE COMPARTMENT) 13 WAY C1 TIPM - (ENGINE COMPARTMENT) 13 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5034 Power Distribution Module: Diagrams Totally Integrated Power Module C2 (Engine Compartment) 14 Way Connector C2 - (ENGINE COMPARTMENT) 14 WAY C2 TIPM - (ENGINE COMPARTMENT) 14 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5035 Power Distribution Module: Diagrams Totally Integrated Power Module C3 (Engine Compartment) 16 Way Connector C3 - (ENGINE COMPARTMENT) 16 WAY C3 TIPM - (ENGINE COMPARTMENT) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5036 Power Distribution Module: Diagrams Inverter Module (Instrument Panel) 9 Way Connector (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY Totally Integrated Power Module C1 (Engine Compartment) 13 Way Connector C1 - (ENGINE COMPARTMENT) 13 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5037 C1 TIPM - (ENGINE COMPARTMENT) 13 WAY Totally Integrated Power Module C2 (Engine Compartment) 14 Way Connector C2 - (ENGINE COMPARTMENT) 14 WAY C2 TIPM - (ENGINE COMPARTMENT) 14 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5038 Totally Integrated Power Module C3 (Engine Compartment) 16 Way Connector C3 - (ENGINE COMPARTMENT) 16 WAY C3 TIPM - (ENGINE COMPARTMENT) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5039 Totally Integrated Power Module C4 (Engine Compartment) 10 Way Connector C4 - (ENGINE COMPARTMENT) 10 WAY C4 TIPM - (ENGINE COMPARTMENT) 10 WAY Totally Integrated Power Module C5 (Engine Compartment) 14 Way Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5040 Connector C5 - (ENGINE COMPARTMENT) 14 WAY C5 TIPM - (ENGINE COMPARTMENT) 14 WAY Totally Integrated Power Module C6 (Engine Compartment) 13 Way Connector C6 - (ENGINE COMPARTMENT) 13 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5041 C6 TIPM - (ENGINE COMPARTMENT) 13 WAY Totally Integrated Power Module C7 (Engine Compartment) 22 Way Connector C7 - (ENGINE COMPARTMENT) 22 WAY C7 TIPM - (ENGINE COMPARTMENT) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5042 Totally Integrated Power Module C8 (Engine Compartment) 22 Way Connector C8 - (ENGINE COMPARTMENT) 22 WAY C8 TIPM - (ENGINE COMPARTMENT) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5043 Totally Integrated Power Module C9 (Battery Feed To TIPM) 1 Way Connector C9 - (BATTERY FEED TO TIPM) 1 WAY C9 TIPM - (BATTERY FEED TO TIPM) 1 WAY Totally Integrated Power Module C10 (Engine Compartment) 8 Way Connector C10 - (ENGINE COMPARTMENT) 8 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5044 C10 TIPM - (ENGINE COMPARTMENT) 8 WAY Totally Integrated Power Module C11 (Engine Compartment) 22 Way Connector C11 - (ENGINE COMPARTMENT) 22 WAY C11 TIPM - (ENGINE COMPARTMENT) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5045 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description Power Distribution Module: Description and Operation Power Inverter Module - Description DESCRIPTION The inverter module is located in the instrument panel. The A/C outlet is mounted in the center console. The inverter module provides A/C power for user accessories. The inverter converts the 12 Volt DC from the battery system to a 110 Volt AC output. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description > Page 5048 Power Distribution Module: Description and Operation Power Inverter Module - Operation OPERATION The AC power outlet receives 12 volts from the Totally Integrated Power Module (TIPM) and passes it as an enable signal to the inverter module. The inverter module also receives 12 volts via the TIPM and inverts this to a 110 volt AC output. The enable signal received from the power outlet enables the inverter to convert the received voltage and pass it to the power outlet to power external devices. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description > Page 5049 Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM) (1). The molded plastic TIPM housing is located in the left front corner of the engine compartment, just behind the air cleaner housing and the battery. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse and relay layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the left inner fender well an indexing pin and one screw. All of the TIPM outputs are through the integral engine compartment wire harness. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description > Page 5050 Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Operation OPERATION All of the current from the generator cable connection goes to the battery through a 10 gauge fusible link that is secured with a nut to the positive battery terminal at the starter. Internal connection of all the Totally Integrated Power Module (TIPM) circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fusible link, fuses and relays are available for service replacement. The TIPM unit cannot be repaired and is only serviced as a unit with the engine compartment wire harness. If the TIPM is inoperative or damaged, the engine compartment wire harness assembly must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Power Distribution Module: Component Tests and General Diagnostics INVERTER MODULE For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 110 VOLT POWER OUTLET DIAGNOSIS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 5053 Power Distribution Module: Programming and Relearning PROGRAMMING 1. Install a battery charger. 2. Verify that the charging rate provides approximately 13.5 volts. NOTE: Do not allow the charger to time out during the reconfiguration process. Set the battery charger timer (if so equipped) to continuous charge. 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 5. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 6. Select "ECU View". 7. Select "TIPMCGW" or "FCMCGW". 8. Select "MISC". 9. Select "Restore Vehicle Configuration". 10. Follow prompts on StarSCAN to complete the reconfigure procedure. 11. Once complete, Wait one minute and turn the ignition key to the "OFF" position. 12. Remove the StarSCAN unit, cable and charger from the vehicle. 13. Verify proper operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal Power Distribution Module: Service and Repair Power Inverter Module - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the shift bezel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Removal 3. Remove the center bezel from the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 4. Remove the fasteners from the mounting brackets of the inverter module. 5. Disconnect the electrical connectors and remove the inverter module. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 5056 Power Distribution Module: Service and Repair Power Inverter Module - Installation INSTALLATION 1. Connect the electrical connectors to the inverter module. 2. Install the fasteners to the mounting brackets. 3. Install the center bezel to the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Install the shift bezel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Installation. 5. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 5057 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) - Removal REMOVAL The TIPM (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. Refer to Wiring Diagrams for more information on the locations of the affected connectors. 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect each of the engine compartment wire harness connectors. 4. Remove the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. 5. Disengage each of the retainers that secure the engine compartment wire harness to the vehicle body and chassis components. 6. Disengage and remove the TIPM housing from its mounting bracket. 7. Remove the TIPM and the engine compartment wire harness from the engine compartment as a unit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 5058 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) Installation INSTALLATION CAUTION: The original Cabin Compartment Node (CCN) and Powertrain Control Module (PCM) must be installed and functioning properly prior to powering up the new Totally Integrated Power Module (TIPM). The TIPM receives vehicle configuration data from the CCN and Vehicle Identification Number (VIN) information from the PCM. If configuration information becomes lost or corrupted, the data can be obtained from DealerCONNECT The Totally Integrated Power Module (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. 1. Position the TIPM in the engine compartment. 2. Align the TIPM on its mounting bracket and install. 3. Route the engine compartment wire harness from the TIPM through the engine compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. Refer to Wiring Diagrams for more information on the harness routing and retainer locations. 4. Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. Refer to Wiring Diagrams for more information on the ground eyelet locations. 5. Reconnect each of the engine compartment wire harness connectors. Refer to Wiring Diagrams for more information on the locations of the affected connectors. 6. Torque nut retaining positive battery cable at TIPM to 96 - 141 Nm (85 - 130 in. lbs.). 7. Reconnect the battery negative cable. 8. Close hood. 9. Verify vehicle and system operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay - Removal Power Distribution Relay: Service and Repair Relay - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay - Removal > Page 5063 Power Distribution Relay: Service and Repair Relay - Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 Power Distribution Module: Locations Totally Integrated Power Module C1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5069 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5070 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5071 Power Distribution Module: Locations Totally Integrated Power Module C2 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5072 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5073 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5074 Power Distribution Module: Locations Totally Integrated Power Module C3 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5075 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5076 Power Distribution Module: Locations Totally Integrated Power Module C4 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5077 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5078 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5079 Power Distribution Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5080 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5081 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5082 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5083 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5084 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5085 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5086 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5087 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5088 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5089 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5090 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5091 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5092 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5093 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5094 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5095 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5096 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5097 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5098 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5099 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5100 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5101 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5102 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5103 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5104 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Totally Integrated Power Module C1 > Page 5105 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way Power Distribution Module: Diagrams Inverter Module (Instrument Panel) 9 Way Connector (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5108 Power Distribution Module: Diagrams Totally Integrated Power Module C1 (Engine Compartment) 13 Way Connector C1 - (ENGINE COMPARTMENT) 13 WAY C1 TIPM - (ENGINE COMPARTMENT) 13 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5109 Power Distribution Module: Diagrams Totally Integrated Power Module C2 (Engine Compartment) 14 Way Connector C2 - (ENGINE COMPARTMENT) 14 WAY C2 TIPM - (ENGINE COMPARTMENT) 14 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5110 Power Distribution Module: Diagrams Totally Integrated Power Module C3 (Engine Compartment) 16 Way Connector C3 - (ENGINE COMPARTMENT) 16 WAY C3 TIPM - (ENGINE COMPARTMENT) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5111 Power Distribution Module: Diagrams Inverter Module (Instrument Panel) 9 Way Connector (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY MODULE-INVERTER (EXCEPT EXPORT) - (INSTRUMENT PANEL) 9 WAY Totally Integrated Power Module C1 (Engine Compartment) 13 Way Connector C1 - (ENGINE COMPARTMENT) 13 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5112 C1 TIPM - (ENGINE COMPARTMENT) 13 WAY Totally Integrated Power Module C2 (Engine Compartment) 14 Way Connector C2 - (ENGINE COMPARTMENT) 14 WAY C2 TIPM - (ENGINE COMPARTMENT) 14 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5113 Totally Integrated Power Module C3 (Engine Compartment) 16 Way Connector C3 - (ENGINE COMPARTMENT) 16 WAY C3 TIPM - (ENGINE COMPARTMENT) 16 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5114 Totally Integrated Power Module C4 (Engine Compartment) 10 Way Connector C4 - (ENGINE COMPARTMENT) 10 WAY C4 TIPM - (ENGINE COMPARTMENT) 10 WAY Totally Integrated Power Module C5 (Engine Compartment) 14 Way Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5115 Connector C5 - (ENGINE COMPARTMENT) 14 WAY C5 TIPM - (ENGINE COMPARTMENT) 14 WAY Totally Integrated Power Module C6 (Engine Compartment) 13 Way Connector C6 - (ENGINE COMPARTMENT) 13 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5116 C6 TIPM - (ENGINE COMPARTMENT) 13 WAY Totally Integrated Power Module C7 (Engine Compartment) 22 Way Connector C7 - (ENGINE COMPARTMENT) 22 WAY C7 TIPM - (ENGINE COMPARTMENT) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5117 Totally Integrated Power Module C8 (Engine Compartment) 22 Way Connector C8 - (ENGINE COMPARTMENT) 22 WAY C8 TIPM - (ENGINE COMPARTMENT) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5118 Totally Integrated Power Module C9 (Battery Feed To TIPM) 1 Way Connector C9 - (BATTERY FEED TO TIPM) 1 WAY C9 TIPM - (BATTERY FEED TO TIPM) 1 WAY Totally Integrated Power Module C10 (Engine Compartment) 8 Way Connector C10 - (ENGINE COMPARTMENT) 8 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5119 C10 TIPM - (ENGINE COMPARTMENT) 8 WAY Totally Integrated Power Module C11 (Engine Compartment) 22 Way Connector C11 - (ENGINE COMPARTMENT) 22 WAY C11 TIPM - (ENGINE COMPARTMENT) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > Inverter Module (Instrument Panel) 9 Way > Page 5120 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description Power Distribution Module: Description and Operation Power Inverter Module - Description DESCRIPTION The inverter module is located in the instrument panel. The A/C outlet is mounted in the center console. The inverter module provides A/C power for user accessories. The inverter converts the 12 Volt DC from the battery system to a 110 Volt AC output. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description > Page 5123 Power Distribution Module: Description and Operation Power Inverter Module - Operation OPERATION The AC power outlet receives 12 volts from the Totally Integrated Power Module (TIPM) and passes it as an enable signal to the inverter module. The inverter module also receives 12 volts via the TIPM and inverts this to a 110 volt AC output. The enable signal received from the power outlet enables the inverter to convert the received voltage and pass it to the power outlet to power external devices. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description > Page 5124 Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Description DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equipment Totally Integrated Power Module (TIPM) (1). The molded plastic TIPM housing is located in the left front corner of the engine compartment, just behind the air cleaner housing and the battery. The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service access and has a convenient fuse and relay layout label affixed to the inside surface of the cover to ensure proper component identification. The TIPM housing is secured to the left inner fender well an indexing pin and one screw. All of the TIPM outputs are through the integral engine compartment wire harness. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Power Inverter Module - Description > Page 5125 Power Distribution Module: Description and Operation Totally Integrated Power Module (TIPM) Operation OPERATION All of the current from the generator cable connection goes to the battery through a 10 gauge fusible link that is secured with a nut to the positive battery terminal at the starter. Internal connection of all the Totally Integrated Power Module (TIPM) circuits is accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for complete circuit diagrams. The fusible link, fuses and relays are available for service replacement. The TIPM unit cannot be repaired and is only serviced as a unit with the engine compartment wire harness. If the TIPM is inoperative or damaged, the engine compartment wire harness assembly must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Power Distribution Module: Component Tests and General Diagnostics INVERTER MODULE For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 110 VOLT POWER OUTLET DIAGNOSIS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 5128 Power Distribution Module: Programming and Relearning PROGRAMMING 1. Install a battery charger. 2. Verify that the charging rate provides approximately 13.5 volts. NOTE: Do not allow the charger to time out during the reconfiguration process. Set the battery charger timer (if so equipped) to continuous charge. 3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 5. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN. 6. Select "ECU View". 7. Select "TIPMCGW" or "FCMCGW". 8. Select "MISC". 9. Select "Restore Vehicle Configuration". 10. Follow prompts on StarSCAN to complete the reconfigure procedure. 11. Once complete, Wait one minute and turn the ignition key to the "OFF" position. 12. Remove the StarSCAN unit, cable and charger from the vehicle. 13. Verify proper operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal Power Distribution Module: Service and Repair Power Inverter Module - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the shift bezel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Removal 3. Remove the center bezel from the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 4. Remove the fasteners from the mounting brackets of the inverter module. 5. Disconnect the electrical connectors and remove the inverter module. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 5131 Power Distribution Module: Service and Repair Power Inverter Module - Installation INSTALLATION 1. Connect the electrical connectors to the inverter module. 2. Install the fasteners to the mounting brackets. 3. Install the center bezel to the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Install the shift bezel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Installation. 5. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 5132 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) - Removal REMOVAL The TIPM (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. Refer to Wiring Diagrams for more information on the locations of the affected connectors. 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Disconnect each of the engine compartment wire harness connectors. 4. Remove the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. 5. Disengage each of the retainers that secure the engine compartment wire harness to the vehicle body and chassis components. 6. Disengage and remove the TIPM housing from its mounting bracket. 7. Remove the TIPM and the engine compartment wire harness from the engine compartment as a unit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Power Inverter Module - Removal > Page 5133 Power Distribution Module: Service and Repair Totally Integrated Power Module (TIPM) Installation INSTALLATION CAUTION: The original Cabin Compartment Node (CCN) and Powertrain Control Module (PCM) must be installed and functioning properly prior to powering up the new Totally Integrated Power Module (TIPM). The TIPM receives vehicle configuration data from the CCN and Vehicle Identification Number (VIN) information from the PCM. If configuration information becomes lost or corrupted, the data can be obtained from DealerCONNECT The Totally Integrated Power Module (TIPM) is serviced as a unit with the engine compartment wire harness. If any internal circuit of the TIPM or the TIPM housing is faulty or damaged, the entire TIPM and engine compartment wire harness unit must be replaced. 1. Position the TIPM in the engine compartment. 2. Align the TIPM on its mounting bracket and install. 3. Route the engine compartment wire harness from the TIPM through the engine compartment, engaging each of the harness retainers to the mounting provisions in the vehicle body and chassis components. Refer to Wiring Diagrams for more information on the harness routing and retainer locations. 4. Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components. Refer to Wiring Diagrams for more information on the ground eyelet locations. 5. Reconnect each of the engine compartment wire harness connectors. Refer to Wiring Diagrams for more information on the locations of the affected connectors. 6. Torque nut retaining positive battery cable at TIPM to 96 - 141 Nm (85 - 130 in. lbs.). 7. Reconnect the battery negative cable. 8. Close hood. 9. Verify vehicle and system operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay - Removal Power Distribution Relay: Service and Repair Relay - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay - Removal > Page 5138 Power Distribution Relay: Service and Repair Relay - Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5142 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5143 Relay Box: Application and ID Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5147 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5148 Relay Box: Application and ID Fuse/Relay Block Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Ride Height Alignment: Specifications Ride Height CURB HEIGHT SPECIFICATIONS - 2.0L GAS ENGINE CURB HEIGHT SPECIFICATIONS - ALL OTHERS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Ride Height > Page 5154 Alignment: Specifications Wheel Alignment WHEEL ALIGNMENT NOTE: All specifications are given in degrees. NOTE: All wheel alignments are to be set with the vehicle at curb height. See: Service and Repair NOTE: Each of the following tables refers to a vehicle equipped with a specific size OEM wheel (except Export). ALL WITH 15 INCH WHEELS ALL WITH 17 INCH WHEELS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Ride Height > Page 5155 ALL WITH 18 INCH WHEELS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Ride Height > Page 5156 SRT4 ALL EXPORT Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Ride Height > Page 5157 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5158 Alignment: Description and Operation DESCRIPTION Vehicle wheel alignment is the positioning of all interrelated front and rear suspension angles. These angles affect the handling and steering of the vehicle when it is in motion. Proper wheel alignment is essential for efficient steering, good directional stability, and proper tire wear. The method of checking a vehicle's front and rear wheel alignment varies depending on the manufacturer and type of equipment used. The manufacturer's instructions should always be followed to ensure accuracy of the alignment, except when Chrysler Corporation's wheel alignment specifications differ. On this vehicle, the suspension angles that can be adjusted are as follows: Front - Camber (with cradle shift or service adjustment bolt package) - Caster (limited adjustment with cradle shift) - Toe Rear - Toe Check the wheel alignment and make all wheel alignment adjustments with the vehicle standing at its proper curb height specification. Curb height is the normal riding height of the vehicle. It is measured from a certain point on the vehicle to the ground or a designated area while the vehicle is sitting on a flat, level surface. Refer to Curb Height Measurement for additional information. See: Service and Repair/Curb Height Measurement Typical wheel alignment angles and measurements are described in the following paragraphs. CAMBER Camber is the inward or outward tilt of the top of the tire and wheel assembly. Inward tilt (2) is known as negative camber. Outward tilt (1) is known as Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5159 positive camber. Camber is measured in degrees of angle relative to a true vertical line. Camber is a tire wearing angle. - Excessive negative camber will cause tread wear at the inside of the tire. - Excessive positive camber will cause tread wear on the outside of the tire. CROSS CAMBER Cross camber is the difference between left and right camber. To achieve the cross camber reading, subtract the right side camber reading from the left. For example, if the left camber is -0.7° and the right camber is -0.5°, the cross camber would be -0.2° (-0.7 - (-0.5) = -0.7 + 0.5 = -0.2). CASTER Caster is the forward or rearward tilt of the steering knuckle in reference to the position of the upper and lower ball joints. Caster is measured in degrees of angle relative to a true vertical center line. This line is viewed from the side of the tire and wheel assembly. - Forward tilt (upper ball joint ahead of lower) results in a negative caster angle. - Rearward tilt (upper ball joint trailing lower) results in a positive caster angle. Although caster does not affect tire wear, a caster imbalance between the two front wheels may cause the vehicle to lead to the side with the least positive caster. CROSS CASTER Cross caster is the difference between left and right caster. To achieve the cross caster reading, subtract the right side caster reading from the left. For example, if the left caster is 2.5° and the right caster is 2.7°, the cross caster would be -0.2° (2.5 - 2.7 = -0.2). TOE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5160 Toe is the inward or outward angle of the wheels as viewed from above the vehicle. - Toe-in (1) is produced when the front edges of the wheels on the same axle are closer together than the rear edges. - Toe-out (2) is produced when the front edges of the wheels on the same axle are farther apart than the rear edges. Toe-in and toe-out can occur at the front wheels and the rear wheels. Toe is measured in degrees or inches. The measurement identifies the amount that the front of the wheels point inward (toe-in) or outward (toe-out). Toe is measured at the spindle height. Zero toe means the front and rear edges of the wheels on the same axle are equal distant. TOE-OUT ON TURNS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5161 Toe-out on turns (1), sometimes referred to as Ackerman Steering, is the relative positioning of the front wheels while steering through a turn. This compensates for each front wheel's turning radius. As the vehicle encounters a turn, the outboard wheel must travel in a larger radius circle than the inboard wheel. The steering system is designed to make each wheel follow its particular radius circle. To accomplish this, the front wheels must progressively toe outward as the steering is turned from center. This eliminates tire scrubbing and undue tire wear when steering a vehicle through a turn. DYNAMIC TOE PATTERN Dynamic toe pattern is the inward and outward toe movement of the front and rear tires through the suspension's jounce and rebound travel. As the vehicle's suspension moves up and down, the toe pattern varies. Toe pattern is critical in controlling the directional stability of the vehicle while in motion. Front and rear dynamic toe pattern is preset by the factory at the time the vehicle is assembled. It is not necessary to check or adjust front or rear dynamic toe pattern when doing a normal wheel alignment. The only time dynamic toe pattern needs to be checked or adjusted is if the frame of the vehicle has been damaged. STEERING AXIS INCLINATION (S.A.I.) Steering axis inclination (1) is the angle between a true vertical line starting at the center of the tire at the road contact point and a line drawn through the center of the upper ball joint (or strut) and the lower ball joint. S.A.I. is built into the vehicle and is not an adjustable angle. If S.A.I. is not within specifications, a bent or damaged suspension component may be the cause. INCLUDED ANGLE (I.A.) Included angle (3) is the sum of the S.A.I. angle (1) plus or minus the camber angle (2), depending on whether or not the wheel has positive or negative camber. If camber is positive, add the camber angle to the S.A.I angle. If camber is negative, subtract the camber angle from the S.A.I. angle. Included angle is not adjustable, but can be used to diagnose a frame misalignment or bent suspension component (spindle, strut). THRUST ANGLE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5162 Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle's center line. The presence of negative or positive thrust angle causes the rear tires to track improperly to the left or right of the front tires (dog tracking). - Negative thrust angle means the rear tires are tracking to the left of the front tires. - Positive thrust angle means the rear tires are tracking to the right of the front tires. Improper tracking can cause undue tire wear, a lead or pull and a crooked steering wheel. Excessive thrust angle can usually be corrected by adjusting the rear wheel toe so that each wheel has one-half of the total toe measurement. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Alignment: Service and Repair Wheel Alignment WHEEL ALIGNMENT PRE-WHEEL ALIGNMENT INSPECTION Before any attempt is made to change or correct the wheel alignment, the following inspection and necessary corrections must be made to the vehicle to ensure proper alignment. 1. Verify the fuel tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the curb height of the vehicle and the alignment specifications. 2. The passenger and luggage compartments of the vehicle should be free of any load that is not factory equipment. 3. Check the tires on the vehicle. The tires are to be inflated to the recommended air pressure. All tires must be the same size and in good condition with approximately the same tread wear. 4. Check the front tire and wheel assemblies for excessive radial runout. 5. Inspect all suspension component fasteners for looseness and proper torque. 6. Inspect the lower front ball joints and all steering linkage for looseness and any sign of wear or damage. 7. Inspect the rubber bushings on all the suspension components for signs of wear or deterioration. If any bushings show signs of wear or deterioration, they should be replaced prior to aligning the vehicle. 8. Check vehicle curb height to verify it is within specifications. See: WHEEL ALIGNMENT SETUP 1. Position the vehicle on an alignment rack. 2. Install all required alignment equipment on the vehicle, per the alignment equipment manufacturer's instructions. On this vehicle, a four-wheel alignment is recommended. NOTE: Prior to reading the vehicle's alignment readouts, the front and rear of vehicle should be jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing each end of vehicle an equal number of times. The bumper should always be released when vehicle is at the bottom of the jounce cycle. 3. Read the vehicle's current front and rear alignment settings. Compare the vehicle's current alignment settings to the vehicle specifications for camber, caster and toe-in. See: Specifications/Wheel Alignment REAR CAMBER Rear camber settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as Net Build. The result is no required adjustment of camber after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, rear camber is not considered an adjustable angle. CAUTION: Do not attempt to adjust the vehicle's wheel alignment by heating or bending any of the suspension components. FRONT CAMBER AND CASTER Front camber and caster settings on this vehicle are determined at the time the vehicle is designed, by the location of the vehicle's suspension components. This is referred to as Net Build. The result is no required adjustment of camber and caster after the vehicle is built or when servicing the suspension components. Thus, when performing a wheel alignment, caster and camber are not normally considered adjustable angles but some adjustment can be made. Camber and caster should be checked to ensure they meet vehicle specifications. See: Specifications/Wheel Alignment If individual front camber or caster is found not to meet alignment specifications, each can be adjusted by shifting the front crossmember or by using an available service adjustment bolt package. If an adjustment bolt package installation is necessary, inspect the suspension components for any signs of damage or bending first. CAUTION: Do not attempt to adjust the vehicle's wheel alignment by heating or bending any of the suspension components. ADJUSTMENT BY SHIFTING CROSSMEMBER CAUTION: Always use care when shifting crossmember to avoid damaging other components on the vehicle. 1. Loosen the four bolts fastening the front crossmember to the frame just enough to allow movement of the crossmember. See: Suspension/Cross-Member/Service and Repair/Crossmember - Removal 2. Loosen the bolts fastening the fore/aft crossmember to the frame just enough to allow movement of the crossmember. See: Suspension/Cross-Member/Service and Repair/Crossmember - Removal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 5165 CAUTION: When shifting the front crossmember, keep in mind that the front and rear engine mounts are attached to the front crossmember and fore/aft crossmember and should be inspected following the crossmember shift to make sure they are properly aligned. 3. Shift front crossmember as necessary (See following tables) to bring camber or caster into specifications. When shifting crossmember, use care not to move other angles (camber or caster) that are within specifications, out of specifications. 4. Tighten all previously loosened fasteners (bolts) securing the crossmember to the vehicle to specifications. See: Suspension/Cross-Member/Service and Repair/Crossmember - Installation 5. Jounce the rear, then front of the vehicle an equal amount of times. 6. Measure camber and caster. If camber and caster are within specifications, proceed to TOE. If camber cannot be brought into specifications, perform the CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION below. CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION The camber adjustment bolt package contains new bolts and nuts for attaching the strut clevis bracket to the steering knuckle. The bolts contained in the package are slightly undersize allowing for movement between the strut clevis bracket and the steering knuckle. The movement allowed by the undersize bolts provide approximately two degrees of camber adjustment per side of the vehicle. To install and adjust the camber adjustment bolt package, follow the procedure below. 1. Raise the vehicle until its tires are not supporting the weight of the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the front tire and wheel assembly (1). CAUTION: The strut clevis-to-knuckle attaching bolt shanks are serrated and must not be turned during removal. Remove the nuts while holding the bolts stationary, then tap the bolts out using a punch. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 5166 3. Remove the original upper bolt (1) and nut (3) attaching the strut clevis bracket (2) to the knuckle (5). 4. Install a bolt from the adjustment package into the hole where the original bolt was removed. Install the bolt as indicated. 5. Install a nut provided in adjustment package on the replacement bolt. Tighten the nut until it's snug, but still allows the knuckle to slide in the clevis bracket. 6. Remove the original lower bolt (6) and nut (4) attaching the strut clevis bracket (2) to the knuckle (5). 7. Install a bolt from the adjustment package into the bottom hole of the strut clevis bracket. Install the bolt as indicated. 8. Install a nut provided in adjustment package on the replacement bolt. Tighten the nut until it's snug, but still allows the knuckle to slide in the clevis bracket. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 5167 9. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 10. Perform the above procedure to opposite strut as required. 11. Lower the vehicle and jounce the front and rear of the vehicle. 12. Adjust the front camber to the preferred setting by pushing or pulling on the top of the tire. When camber is set to specifications, tighten the upper and lower strut clevis-to-knuckle attaching bolt nuts (3, 4) enough to hold the adjustment. Again jounce the front and rear of the vehicle, then verify the camber settings. 13. Tighten the front strut clevis-to-knuckle attaching bolt nuts (3, 4) to 110 Nm (81 ft. lbs.). 14. Once camber is within specifications, adjust toe to meet the preferred specification setting. Refer to FRONT TOE within this wheel alignment service procedure. TOE 1. Center the steering wheel and lock it in place using a steering wheel clamp. NOTE: When setting toe, make sure to set rear toe to the preferred specifications before setting front toe to the preferred specifications REAR TOE NOTE: Perform the following at each rear wheel as necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 5168 1. While holding the cam bolt head (3) stationary, loosen the toe link mounting cam bolt nut (1). 2. Rotate the cam bolt head (3) left or right until the rear wheel toe for that rear wheel is set to the preferred specification. See: Specifications/Wheel Alignment 3. While holding the cam bolt head (3) stationary, tighten the toe link mounting cam bolt nut (1) to 25 Nm (18 ft. lbs.). FRONT TOE NOTE: Perform the following at each front wheel as necessary. CAUTION: Do not twist the inner tie rod-to-steering gear boot (bellows) while turning the inner tie rod during front toe adjustment. It may be necessary to remove the clamp where the boot meets the inner tie rod. 1. Loosen the tie rod adjusting jam nut (1). Grasp the inner tie rod (3) and rotate it one way or the other until the front wheel toe is set to the preferred specification. See: Specifications/Wheel Alignment 2. Tighten the tie rod adjusting jam nut to of 75 Nm (55 ft. lbs.). 3. Make sure the inner tie rod-to-steering gear boot is not twisted. If removed, reinstall the clamp where the boot meets the inner tie rod. 4. Remove the steering wheel clamp. 5. Remove the alignment equipment. 6. Road test the vehicle to verify the steering wheel is straight and the vehicle does not pull or wander. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 5169 Alignment: Service and Repair Curb Height Measurement CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring is weak. NOTE: Prior to reading the curb height measurement, the front and rear of the vehicle must be jounced to settle the suspension. Induce jounce by pushing down on the center of the bumper (fascia), using care not to damage the vehicle, moving the vehicle up and down, gradually increasing the suspension travel with each stroke. Release the bumper at the bottom of each stroke, repeating this action several times. Perform this to both front and rear suspensions an equal amount of times. Measure curb height as follows: 1. Jounce the vehicle. Refer to above note. NOTE: On some vehicles it may be necessary to remove an engine belly pan in order to gain access to the lower control arm pivot bolt. 2. FRONT - On each side of the vehicle, measure the distance (2) from the lower control arm rear (vertical) pivot bolt head (1) to the floor or alignment rack/lift runway surface. It may be necessary to measure to the bottom of a straight edge (3), placed from lift runway to runway, to get an accurate measurement. 3. REAR - On each side of the vehicle, measure the distance (2) from the center of the outboard trailing arm-to-body mounting bolt (1) to the floor or Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment > Page 5170 alignment rack/lift runway surface. 4. Compare the measurements to specifications listed in the following CURB HEIGHT SPECIFICATIONS chart. Maximum left-to-right differential is not to exceed 12.5 mm (0.5 in.). 5. If curb height is found to be out of specification and there is no sign of excessive body damage, curb height can be changed by replacing the applicable spring with a spring offering a different check load. See: Suspension/Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Strut / Shock/Removal CURB HEIGHT SPECIFICATIONS - 2.0L GAS ENGINE CURB HEIGHT SPECIFICATIONS - ALL OTHERS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 5176 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C1 (Instrument Panel) 4 Way Steering Mounted Controls Communication Module: Diagrams Steering Control Module C1 (Instrument Panel) 4 Way Connector C1 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C1 (Instrument Panel) 4 Way > Page 5179 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C2 (Instrument Panel) 6 Way Connector C2 - (INSTRUMENT PANEL) 6 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C1 (Instrument Panel) 4 Way > Page 5180 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C4 (Instrument Panel) 4 Way Connector C4 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation/Communication - Description. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 5183 Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 5184 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation/Communication - Description. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 5185 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. SCCM 1. Place the front road wheels in the STRAIGHT-AHEAD position. 2. Disconnect and isolate the negative battery cable. 3. Remove steering wheel See: Steering/Steering Wheel/Service and Repair/Removal. 4. Remove upper and lower steering column shrouds to gain access to the Steering Column Control Module (SCCM) (3) See: Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 5. Lock the clockspring rotor in the center position as follows: Insert a pin through the hole in the rotor at the 10 o'clock position. 6. Remove the three screws (1) to the SCCM. 7. Disconnect the electrical connectors (2) between the SCCM (1) and the instrument panel wiring harness at the base of the SCCM and remove from column. DISASSEMBLY NOTE: There is no need to disassemble the Steering Column Control Module (SCCM) if only removing the SCCM from the column. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 5188 1. Remove the left multi-function switch stalk retaining screw (2). 2. Pull the left stalk out of the SCCM. 3. Disconnect the left stalk electrical connector. 4. Separate the left switch from the SCCM. 5. Remove the one right multi-function switch retaining screw. 6. Pull right switch out of SCCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 5189 7. Disconnect the right switch electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 5190 Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Installation INSTALLATION NOTE: If SCCM is already assembled and needs to be installed, bypass ASSEMBLY and proceed with SCCM 1. ASSEMBLY 1. Connect the right stalk electrical connector. 2. Slide the right stalk into the groove and install the one retaining screw. 3. Connect the left stalk switch electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 5191 4. Install the left stalk switch retaining screw. SCCM 1. Position the SCCM (3) over the steering column shaft (2). 2. Install the three screws (1). 3. Connect the electrical connectors (2) to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged. 4. Install steering column shrouds See: Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. Be sure all wires are inside of shrouds. 5. Install steering wheel ensuring the flats on hub align with the clockspring See: Steering/Steering Wheel/Service and Repair/Installation. Pull the airbag leads through the larger slot. Ensure leads do not get pinched under the steering wheel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 5192 NOTE: There is a small wire harness in the steering wheel and it contains the horn circuits and speed control circuits. 6. Connect the speed control and horn wire connector into the clockspring. 7. Pull the grenade pin out of the clockspring. 8. Install the driver airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Installation WARNING: Do not connect the negative battery cable at this time. Perform the Air Bag System Test prior to connecting the negative battery cable See: Restraint Systems/Testing and Inspection . Failure to follow this warning may result in accidental air bag deployment and possible serious or fatal injury. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 5198 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 5199 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Tire Pressure Monitor Receiver / Transponder: Diagrams Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT FRONT (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way > Page 5202 Tire Pressure Monitor Receiver / Transponder: Diagrams Left Rear Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT REAR (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way > Page 5203 Tire Pressure Monitor Receiver / Transponder: Diagrams Right Rear Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-RIGHT REAR (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Description DESCRIPTION A transponder, sometimes referred to as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of a vehicle equipped with Premium TPM. These transponders are used to provide the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. On this vehicle, there is a transponder located in the left front, left rear, and right rear wheelhouse. There is not a transponder located in the right front wheelhouse. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description > Page 5206 Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Operation OPERATION On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (The auto-locating process will start again only if the vehicle has been shut off for approximately 20 minutes or longer). Once the WCM has performed this to the three locations that have transponders, it uses the process-of-elimination theory to figure out the location of the fourth sensor ID. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Removal Front FRONT 1. Remove the wheelhouse splash shield at the transponder requiring service. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 2. Disconnect the wiring harness connector (2) at the transponder (1). 3. Remove the mounting nuts (3), then remove the transponder (1). Rear REAR 1. Remove the wheelhouse splash shield at the transponder requiring service. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 2. Disconnect the wiring harness connector (3) at the transponder (1). 3. Remove the mounting nuts (2), then remove the transponder (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 5209 Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Installation Front FRONT 1. Position the transponder (1) and install the mounting nuts (3). 2. Connect the wiring harness connector (2) to the transponder (1). 3. Install the wheelhouse splash shield and all components removed to access it. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test. Rear REAR 1. Position the transponder (1) and install the mounting nuts (2). 2. Connect the wiring harness connector (3) to the transponder (1). 3. Install the rear wheelhouse splash shield and all components removed to access it. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The Tire Pressure Monitoring (TPM) system has been optimized for the original equipment tires and wheels. TPM system pressures have been established for the tire size equipped on the vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, or style. Aftermarket wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with TPM, as damage to the sensors may result. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: When installing the valve core, be sure to tighten the core to specifications See: Wheels and Tires/Wheels/Specifications . Overtightening by a little as three or four inch pounds can damage the sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a white outline oval (black center) insignia (3) on the sensor body. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 5217 The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by either a solid white oval insignia (3) on the body or. . a solid white oval insignia (3) with 433 printed in the center. The sensors are identical except for the oval insignia. The 433 MHz sensors can either have a black or grey sensor body. CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Sensors may be identified by valve stem cap color. From the factory, 315 MHz sensors have a gray valve stem cap while 433 MHz sensors have a black valve stem cap. Otherwise, once mounted inside a tire and wheel assembly you are not able to visually tell the difference between a 315 MHz and 433 MHz sensor. At that point, the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 5218 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 5219 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer, or from a transponderSee: Relays and Modules - Steering and Suspension/Relays and Modules - Wheels and Tires/Tire Pressure Monitor Receiver / Transponder/Description and Operation/Tire Pressure Monitoring (TPM) Transponder - Operation. The TPM-RKE Analyzer has the ability to change the sensor's operating mode to PARK MODE and to help diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following operating modes: - SLEEP MODE - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. PARK MODE - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 psi (6.9 kPa) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 BLOCK MODE - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to PARK MODE using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph (24 km/h). In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 10 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to DRIVE MODE. - DRIVE MODE - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). Anytime the vehicle speed drops below 15 mph (24 km/h), the sensor mode will still be in Drive Mode, but will not transmit until the vehicle reaches speeds over 15 mph (24 km/h) once again. If the vehicle has been stationary for more then 20 minutes, the sensor state will transition to Park Mode. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 mph (24 km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The WCM can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 5222 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 5223 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 5224 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the outer and inner tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. 8. Remove the support and lower the vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 5225 b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation DESCRIPTION The knuckle (1) is a single casting with legs machined for attachment to the front strut assembly on the top, lower control arm ball joint on the bottom, and steering linkage on the trailing end. The knuckle also has two machined, drilled and tapped legs on the leading end casting to support and align the front disc brake caliper adapter. The knuckle supports the wheel bearing (5) and hub (3). The hub is pressed into a sealed-for-life wheel bearing that is pressed into the knuckle. A snap ring also holds the bearing in place. A shield is pressed onto the knuckle behind the hub. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation > Page 5230 Front Steering Knuckle: Testing and Inspection KNUCKLE The front suspension knuckle is not a repairable component of the front suspension. It must be replaced if found to be damaged in any way. If it is determined that the knuckle is bent when servicing the vehicle, no attempt is to be made to straighten the knuckle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal Front Steering Knuckle: Service and Repair Front Steering Knuckle - Removal REMOVAL NOTE: Before proceeding, review all Warnings and Cautions. See: Suspension/Service Precautions/Technician Safety Information 1. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove cotter pin (1), lock (7) and spring washer (2) from halfshaft stub shaft (5). 4. While a helper applies the brakes to keep the hub (1) from rotating, remove the hub nut (3) and washer (6). 5. Access and remove the front brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 5233 6. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (4). 7. Remove the screw (2) fastening the wheel speed sensor head (3) to the knuckle (4). Pull the sensor head out of the knuckle. 8. Remove the nut (2) attaching the outer tie rod (7) to the knuckle (3). To do this, hold the tie rod end stud with a wrench while loosening and removing the nut with a standard wrench or crowfoot wrench. 9. Release the outer tie rod end (3) from the knuckle (2) using Remover 9360 (1). 10. Remove the outer tie rod from the knuckle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 5234 11. Remove the nut (5) and pinch bolt (4) clamping the ball joint stud (6) to the knuckle (3). CAUTION: The strut assembly-to-knuckle attaching bolts (5) are serrated and must not be turned during removal. Proper removal is required. Refer to the following steps for the correct method. 12. While holding the bolt heads stationary, remove the two nuts (2) from the bolts (5) attaching the strut (3) to the knuckle (6). 13. Remove the two bolts (5) attaching the strut (3) to the knuckle (6) using a pin punch. CAUTION: Use care when separating the ball joint stud (4) from the knuckle (1), so the ball joint seal does not get cut. 14. Using an appropriate prying tool (2), separate the ball joint stud (4) from the knuckle (1) by prying down on lower control arm (3) and up against the ball joint boss on the knuckle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 5235 NOTE: Do not allow the half shaft (1) to hang by the inner C/V joint; it must be supported to keep the joint from separating during this operation. 15. Pull the knuckle (3) off the half shaft (1) outer C/V joint splines and remove the knuckle from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 5236 Front Steering Knuckle: Service and Repair Front Steering Knuckle - Installation INSTALLATION 1. Slide the hub of the knuckle (3) onto the splines of the halfshaft outer C/V joint (1). 2. Install the knuckle (3) onto the ball joint (6) stud aligning the bolt hole in the knuckle boss with the groove formed into the side of the ball joint stud. 3. Install a NEW ball joint stud pinch bolt (4) and nut (5). Tighten the nut to 82 Nm (60 ft. lbs.). CAUTION: The strut assembly-to-knuckle attaching bolts (2) are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the steering knuckle. Refer to the following step. 4. Position the lower end of the strut assembly (3) in line with the upper end of the knuckle (6), aligning the mounting holes. Install the two mounting bolts (5). 5. Install the nuts (2) on the two bolts (5). While holding the bolts in place, tighten the nuts to 110 Nm (81 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 5237 6. Install the outer tie rod (7) ball stud into the hole in the knuckle (3) arm. Start the tie rod end-to-knuckle nut (2) onto the stud. While holding the tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench to 132 Nm (97 ft. lbs.). 7. Install the wheel speed sensor head (3) into the knuckle (4). Install the mounting screw (2) and tighten it to 12 Nm (106 in. lbs.). 8. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (4). 9. Install the brake rotor, disc brake caliper and adapter. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation 10. Clean all foreign matter from the threads of the halfshaft stub shaft. 11. Install the washer (6) and hub nut (3) on end of halfshaft stub shaft (5). While a helper applies the brakes to keep the hub (4) from rotating, tighten the hub nut to 244 Nm (180 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 5238 12. Install the spring washer (2) and hub nut lock (7) over the hub nut and stub shaft. Install a NEW cotter pin (1) securing nut lock in place and wrap the cotter pin prongs tightly around the nut lock. 13. Install tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 14. Lower the vehicle. NOTE: If the original knuckle is being reinstalled, wheel alignment may not be necessary due to Net-Build design. 15. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair POWER STEERING SYSTEM BLEEDING WARNING: The fluid level should be checked with engine off to prevent injury from moving components. CAUTION: Mopar(R) Power Steering Fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid is to be used in the power steering system. Both Fluids have the same material standard specifications (MS-9602). No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if another fluid is used. Do not overfill the system. CAUTION: If the air is not purged from the power steering system correctly, pump failure could result. NOTE: Be sure the vacuum tool used in the following procedure is clean and free of any fluids. 1. Check the fluid level. As measured on the side of the reservoir, the level should indicate between MAX and MIN when the fluid is at normal ambient temperature. Adjust the fluid level as necessary.See: Service and Repair/Power Steering Fluid Level Checking 2. Tightly insert Power Steering Cap Adapter (4), Special Tool 9688, into the mouth of the reservoir (3). CAUTION: Failure to use a vacuum pump reservoir (1) may allow power steering fluid to be sucked into the hand vacuum pump. 3. Attach Hand Vacuum Pump (2), Special Tool C-4207 or equivalent, with reservoir (1) attached, to the Power Steering Cap Adapter (4). CAUTION: Do not run the vehicle while vacuum is applied to the power steering system. Damage to the power steering pump can occur. NOTE: When performing the following step make sure the vacuum level is maintained during the entire time period. 4. Using Hand Vacuum Pump (2), apply 68-85 kPa (20-25 in. Hg) of vacuum to the system for a minimum of three minutes. 5. Slowly release the vacuum and remove the special tools. 6. Adjust the fluid level as necessary. Refer to 1. 7. Repeat 1 through 6 until the fluid no longer drops when vacuum is applied. 8. Start the engine and cycle the steering wheel lock-to-lock three times. NOTE: Do not hold the steering wheel at the stops. 9. Stop the engine and check for leaks at all connections. 10. Check for any signs of air in the reservoir and check the fluid level. If air is present, repeat the procedure as necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5247 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 5248 Power Steering Fluid: Specifications Mopar Power Steering Fluid +4 or Mopar ATF+4. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 5249 Power Steering Fluid: Description and Operation POWER STEERING FLUID The recommended fluid for the power steering system is Mopar(R) Power Steering fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid. Both Fluids have the same material standard specifications (MS-9602). Mopar(R) ATF+4 (and Mopar(R) Power Steering fluid + 4), when new, is red in color. ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. The power steering system is filled-for-life at the factory and requires no regular maintenance. Although not required at specific intervals, the fluid level may be checked periodically. Check the fluid level anytime there is a system noise or fluid leak suspected. See: Service and Repair/Power Steering Fluid Level Checking Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 5250 Power Steering Fluid: Service and Repair POWER STEERING FLUID LEVEL CHECKING WARNING: Fluid level should be checked with the engine OFF to prevent personal injury from moving parts and to assure an accurate fluid level reading. CAUTION: Mopar(R) Power Steering Fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid is to be used in the power steering system. Both fluids have the same material standard specifications (MS-9602). No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if another fluid is used. Do not overfill the system. NOTE: Although not required at specific intervals, the fluid level may be checked periodically. Check the fluid level anytime there is a system noise or fluid leak suspected. The power steering fluid level can be viewed through the side of the power steering fluid reservoir. Compare the fluid level to the markings on the side of the reservoir. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should read between the MAX. and MIN. markings. When the fluid is hot, fluid level is allowed to read up to the MAX. line. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Description and Operation Power Steering Fluid Cooler: Description and Operation DESCRIPTION The cooler (4) is placed in series with the power steering fluid return hose (1), between the steering gear fluid outlet port and the fluid return hose leading to the power steering fluid reservoir. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Power Steering Cooler - Removal Power Steering Fluid Cooler: Service and Repair Power Steering Cooler - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions . 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair. 3. Remove right front wheel mounting nuts and the tire and wheel assembly. 4. Remove the right front splash shield See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 5. Remove the hose clamps (2) attaching the fluid return hose (1) to the power steering fluid cooler line. Separate the return hose from the cooler line (4). 6. Remove the cooler tubes from the clips (3) on the side of the frame rail. 7. Remove the cooler lines (4) from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Power Steering Cooler - Removal > Page 5256 Power Steering Fluid Cooler: Service and Repair Power Steering Cooler - Installation INSTALLATION 1. Install the cooler tubes in the clips (3) on the side of the frame rail. 2. Install the fluid return hose (1) on the power steering fluid cooler lines (4). Install the hose clamps (2) on the hoses past the bead formed into the end of the cooler tube and secure in place. 3. Install the right front splash shield See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 4. Install tire and wheel assembly See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation 5. Lower the vehicle. 6. Fill and bleed the power steering system. See: Service and Repair/Power Steering System Bleeding 7. Check for leaks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Description and Operation Power Steering Fluid Reservoir: Description and Operation DESCRIPTION The power steering fluid reservoir (5) is mounted above the right front inner fender well to a bracket (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Reservoir, Power Steering Pump - Removal Power Steering Fluid Reservoir: Service and Repair Reservoir, Power Steering Pump - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions . 1. Remove engine appearance cover. 2. Remove the fasteners securing the coolant recovery bottle to its mounts and move it away from the power steering fluid reservoir. It is not necessary to disconnect the coolant recovery bottle fluid lines. See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Removal 3. Siphon as much fluid as possible from the power steering fluid reservoir (5). 4. Remove hose clamp securing cooler return hose (3) to fluid reservoir fitting. Slide the hose off the end of the reservoir fitting. 5. Remove hose clamp securing pump supply hose (4) to the fluid reservoir fitting. Slide the hose off the end of the reservoir fitting. 6. Remove the reservoir mounting screw (1) used to secure the reservoir in place. 7. Remove the reservoir (5). 8. Remove the plastic shield from the reservoir. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Reservoir, Power Steering Pump - Removal > Page 5262 Power Steering Fluid Reservoir: Service and Repair Reservoir, Power Steering Pump - Installation INSTALLATION 1. Install the plastic shield over the reservoir neck. 2. Attach the reservoir (5) to the strut tower bracket (2) using the mounting screw (1). Tighten mounting screw (1) to 12 Nm (106 in. lbs.). 3. Slide the pump supply hose (4) onto reservoir fitting. Expand hose clamp and slide it over hose on reservoir fitting. Secure clamp once it is past bead formed into fluid reservoir fitting. 4. Slide cooler return hose (3) onto reservoir fitting. Expand hose clamp and slide it over hose on reservoir fitting. Secure clamp once it is past bead formed into fluid reservoir fitting. 5. Install the coolant recovery bottle. See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Installation 6. Fill and bleed the power steering system. See: Service and Repair/Power Steering System Bleeding 7. Check for leaks. 8. Install the engine appearance cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Testing and Inspection Power Steering Line/Hose: Testing and Inspection POWER STEERING PUMP AND HOSES NOTE: This information is designed to be used in conjunction with the diagnostic charts at the beginning of the Steering section. See: Testing and Inspection CHECKING FOR WEAR OF POWER STEERING PUMP INTERNAL COMPONENTS 1. Place gear selector in PARK (or NEUTRAL) with wheels chalked. 2. With the engine idling, have a helper turn the steering wheel. 3. Using an electronic listening tool, determine if noise is coming from the pump. 4. Increase the engine speed and have a helper turn the steering wheel. Does the noise change with load? 5. Replace the power steering pump if excessive noise is present. See: Power Steering Pump/Service and Repair/Power Steering Pump - Removal CHECKING FOR POWER STEERING HOSES TOUCHING BODY OR FRAME OF VEHICLE Check hoses and hose tubes as following: - Inspect hoses and hose tubes for witness marks. If witness marks are present, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque See: Specifications. Do not bend tubing to adjust. Replace the hose assembly if damaged. - Check fastener torque of hose mounting brackets and tube nuts. See: Specifications - Have a helper bump the steering gear off of the stops to induce pressure fluctuations which may move the hose. If hose contact is made, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque See: Specifications. Do not bend tubing to adjust. Replace the hose assembly if damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal Power Steering Line/Hose: Service and Repair Power Steering Hose - Removal Pressure Hose GAS ENGINE NOTE: Before proceeding, See: Service Precautions . 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the engine appearance cover. 3. Remove the pressure Hose (3) at the pump pressure port (5). 4. Remove the pressure hose routing bracket bolt (2) at the upper mount (8). 5. Remove the pressure hose routing clamp bolt (1) at the exhaust manifold. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 5268 6. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 7. Remove the return hose (1) at the return tube (2). 8. Remove the return tube (1) at the steering gear (3). 9. Remove the pressure hose (2) at the steering gear (3). 10. Remove the fasteners (1) securing the power steering hose routing clamps (2) to the crossmember. 11. Remove the power steering pressure hose from the vehicle. Return Hose REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 5269 NOTE: Before proceeding, See: Service Precautions . 1. Remove the engine appearance cover. 2. Remove the coolant recovery bottle. See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Removal 3. Siphon as much fluid as possible from the power steering fluid reservoir. 4. Remove the power steering fluid reservoir.See: Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Removal 5. Remove the windshield washer reservoir.See: Wiper and Washer Systems/Windshield Washer Reservoir/Service and Repair/Windshield Washer Reservoir - Removal 6. Remove the front fascia. See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Removal 7. Remove the right headlamp. See: Lighting and Horns/Service and Repair/Front Lamp Unit Removal 8. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 9. Remove the return hose (1) at the return tube (2). 10. Remove the return hose routing clamp screw (2) securing the return hose (7) to the frame rail. 11. Lower the vehicle. 12. Remove the return hose routing clamp screw (1) securing the return hose (7) to the strut tower. 13. Remove the hose clamps (6) securing the return hose to the power steering reservoir and cooler. Slide the hose off the end of the cooler tube. 14. Remove the return hose from the vehicle. Supply Hose GAS ENGINE NOTE: Before proceeding, See: Service Precautions . Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 5270 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the clamp (2) securing the supply hose to the power steering pump (3) supply fitting, then remove the hose from the supply fitting. 3. Remove the hose clamp securing the supply hose (4) to the power steering fluid reservoir (5). Slide the hose off the end of the reservoir fitting and remove from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 5271 Power Steering Line/Hose: Service and Repair Power Steering Hose - Installation Pressure Hose GAS ENGINE CAUTION: Power steering fluid hoses must remain away from the exhaust system, driveshafts, vehicle components and any unfriendly surface that can possibly damage the hoses. 1. Using a lint free towel, wipe clean the open power steering hose end and the power steering pump port. Replace any used O-rings with new. Lubricate the O-ring with power steering fluid. 2. Install the power steering pressure hose into the engine compartment from below. 3. Install the fasteners (1) securing the power steering hose routing clamps (2) to the crossmember. Use a NEW push clip on the left and tighten the screw on the right to 8 Nm (71 in. lbs.). 4. Install the pressure hose (2) at the gear (3). Tighten the tube nut to 32 Nm (24 ft. lbs.). 5. Install the return tube (1) at the gear (3). Tighten the tube nut to 20 Nm (15 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 5272 6. Install the return hose (1) at the return tube (2). 7. Lower the vehicle. 8. Install the pressure hose (3) at the pump pressure port (5). Tighten the tube nut to 32 Nm (24 ft. lbs.). 9. Install the pressure hose routing bracket bolt (2) to the upper mount (8). 10. Position the pressure hose routing clamp (2) at the exhaust manifold and install the mounting bolt (1). Tighten the bolt to 9 Nm (80 in. lbs.). 11. Fill and bleed the power steering system. See: Service and Repair/Power Steering System Bleeding 12. Check for leaks. 13. Install the engine appearance cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 5273 Return Hose INSTALLATION 1. Install the power steering return hose (7) into the engine compartment. 2. Install the return hose routing clamp screw (1) securing the return hose (7) to the strut tower. 3. Install the return hose onto the cooler tubes (5) and install the hose clamps (6). 4. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 5. Install the screw (2) securing the return hose to the frame rail. Tighten the screw to 19 Nm (14 ft. lbs.). 6. Install the return hose (1) at the return tube (2). 7. Lower the vehicle. 8. Install the right headlamp. See: Lighting and Horns/Service and Repair/Front Lamp Unit Installation 9. Install the front fascia. See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Installation 10. Install the windshield washer reservoir. See: Wiper and Washer Systems/Windshield Washer Reservoir/Service and Repair/Windshield Washer Reservoir - Installation 11. Install the power steering fluid reservoir. See: Power Steering Fluid Reservoir/Service and Repair/Reservoir, Power Steering Pump - Installation 12. Install the coolant recovery bottle. See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Coolant Recovery Bottle - Installation 13. Fill and bleed the power steering system. See: Service and Repair/Power Steering System Bleeding 14. Check for leaks. 15. Install the engine appearance cover. Supply Hose Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 5274 GAS ENGINE 1. Slide hose clamps (2) onto both ends of the power steering fluid supply hose (1) far enough to clear the fittings on the reservoir and pump once the hose is installed. 2. Place the pump end of the supply hose (1) onto the pump (3) supply fitting. Expand the hose clamp (2) and slide it over the hose and pump supply fitting. Secure the clamp once it is past the bead formed into the fluid supply fitting. 3. Expand the hose clamp (4) at the fluid reservoir (5) and slide it over the hose and fitting. Secure the clamp once it is past the bead formed into the fluid reservoir fitting. 4. Perform the POWER STEERING PUMP BLEED PROCEDURE. See: Service and Repair/Power Steering System Bleeding 5. Check for leaks at all hose connections. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Description and Operation Power Steering Pump: Description and Operation DESCRIPTION Hydraulic pressure for operation of the power steering gear is provided by a droop-flow type power steering pump. The power steering pump is belt driven. The pulley (1) cannot be serviced separately. The power steering pump is serviced as a complete assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Description and Operation > Page 5278 Power Steering Pump: Testing and Inspection POWER STEERING PUMP AND HOSES NOTE: This information is designed to be used in conjunction with the diagnostic charts at the beginning of the Steering section. See: Testing and Inspection CHECKING FOR WEAR OF POWER STEERING PUMP INTERNAL COMPONENTS 1. Place gear selector in PARK (or NEUTRAL) with wheels chalked. 2. With the engine idling, have a helper turn the steering wheel. 3. Using an electronic listening tool, determine if noise is coming from the pump. 4. Increase the engine speed and have a helper turn the steering wheel. Does the noise change with load? 5. Replace the power steering pump if excessive noise is present. See: Service and Repair/Power Steering Pump - Removal CHECKING FOR POWER STEERING HOSES TOUCHING BODY OR FRAME OF VEHICLE Check hoses and hose tubes as following: - Inspect hoses and hose tubes for witness marks. If witness marks are present, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque See: Specifications. Do not bend tubing to adjust. Replace the hose assembly if damaged. - Check fastener torque of hose mounting brackets and tube nuts. See: Specifications - Have a helper bump the steering gear off of the stops to induce pressure fluctuations which may move the hose. If hose contact is made, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque See: Specifications. Do not bend tubing to adjust. Replace the hose assembly if damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump - Removal Power Steering Pump: Service and Repair Power Steering Pump - Removal GAS ENGINE NOTE: Before proceeding, See: Service Precautions . 1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the engine appearance cover. 3. If equipped with a non-turbo engine: a. Remove the pressure hose routing bracket bolt (2) at the upper mount (8). b. Remove the pressure hose (3) at the pump pressure port (5). 4. If equipped with a turbo engine, remove the pressure Hose (3) at the pump (2) pressure port. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump - Removal > Page 5281 5. Remove the hose clamp (2) securing the supply hose (1) at the pump. 6. Remove the supply hose (1) from the pump (3). 7. Remove the drive belt (2). See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal 8. Remove the three pump mounting bolts (1) through the pulley (3) openings. 9. Remove the power steering pump. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump - Removal > Page 5282 Power Steering Pump: Service and Repair Power Steering Pump - Installation GAS ENGINE 1. Using a lint free towel, wipe clean the open power steering pressure hose end and the power steering pump port. Replace any used O-rings with new. Lubricate the O-ring with clean power steering fluid. 2. Place the pump in mounting position. Install the three bolts (1) through the pulley (3) openings. Tighten the mounting bolts (1) to 26 Nm (19 ft. lbs.). 3. Install the drive belt (2). See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation 4. Install the supply hose (1) at the pump (3). 5. Clamp the hose clamp (2) securing the supply hose (1) to the pump. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump - Removal > Page 5283 6. If equipped with a non-turbo engine: a. Install the pressure hose (3) at the pump pressure port (5). Tighten the tube nut to 32 Nm (24 ft. lbs.). b. Install the pressure hose routing bracket bolt (2) to the upper mount (8). 7. If equipped with a turbo engine, install the pressure hose (3) at the pump (2) pressure port. Tighten the tube nut (1) to 32 Nm (24 ft. lbs.). 8. Fill and bleed the power steering system. See: Service and Repair/Power Steering System Bleeding 9. Check for leaks. 10. Install the engine appearance cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 5288 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C1 (Instrument Panel) 4 Way Steering Mounted Controls Communication Module: Diagrams Steering Control Module C1 (Instrument Panel) 4 Way Connector C1 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C1 (Instrument Panel) 4 Way > Page 5291 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C2 (Instrument Panel) 6 Way Connector C2 - (INSTRUMENT PANEL) 6 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C1 (Instrument Panel) 4 Way > Page 5292 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C4 (Instrument Panel) 4 Way Connector C4 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module Description Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation/Communication - Description. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module Description > Page 5295 Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module Description > Page 5296 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation/Communication - Description. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module Description > Page 5297 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module Removal Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. SCCM 1. Place the front road wheels in the STRAIGHT-AHEAD position. 2. Disconnect and isolate the negative battery cable. 3. Remove steering wheel See: Steering Wheel/Service and Repair/Removal. 4. Remove upper and lower steering column shrouds to gain access to the Steering Column Control Module (SCCM) (3) See: Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 5. Lock the clockspring rotor in the center position as follows: Insert a pin through the hole in the rotor at the 10 o'clock position. 6. Remove the three screws (1) to the SCCM. 7. Disconnect the electrical connectors (2) between the SCCM (1) and the instrument panel wiring harness at the base of the SCCM and remove from column. DISASSEMBLY NOTE: There is no need to disassemble the Steering Column Control Module (SCCM) if only removing the SCCM from the column. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module Removal > Page 5300 1. Remove the left multi-function switch stalk retaining screw (2). 2. Pull the left stalk out of the SCCM. 3. Disconnect the left stalk electrical connector. 4. Separate the left switch from the SCCM. 5. Remove the one right multi-function switch retaining screw. 6. Pull right switch out of SCCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module Removal > Page 5301 7. Disconnect the right switch electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module Removal > Page 5302 Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Installation INSTALLATION NOTE: If SCCM is already assembled and needs to be installed, bypass ASSEMBLY and proceed with SCCM 1. ASSEMBLY 1. Connect the right stalk electrical connector. 2. Slide the right stalk into the groove and install the one retaining screw. 3. Connect the left stalk switch electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module Removal > Page 5303 4. Install the left stalk switch retaining screw. SCCM 1. Position the SCCM (3) over the steering column shaft (2). 2. Install the three screws (1). 3. Connect the electrical connectors (2) to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged. 4. Install steering column shrouds See: Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. Be sure all wires are inside of shrouds. 5. Install steering wheel ensuring the flats on hub align with the clockspring See: Steering Wheel/Service and Repair/Installation. Pull the airbag leads through the larger slot. Ensure leads do not get pinched under the steering wheel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module Removal > Page 5304 NOTE: There is a small wire harness in the steering wheel and it contains the horn circuits and speed control circuits. 6. Connect the speed control and horn wire connector into the clockspring. 7. Pull the grenade pin out of the clockspring. 8. Install the driver airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Installation WARNING: Do not connect the negative battery cable at this time. Perform the Air Bag System Test prior to connecting the negative battery cable See: Restraint Systems/Testing and Inspection . Failure to follow this warning may result in accidental air bag deployment and possible serious or fatal injury. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Shroud - Removal Steering Column Cover: Service and Repair Steering Column Shroud - Removal Upper REMOVAL 1. Position the column tilt at the full-downward position. 2. Remove the two screws (4) attaching the upper shroud (1) to the lower shroud (2). After removing the screws, unclip the shrouds from each other by applying hand pressure along the seams where the shrouds connect on the sides, then remove the upper shroud. Lower REMOVAL Special Tools 1. Remove the screws (2) from the bottom of the steering column opening cover (1). 2. Using Trim Stick C-4755 separate the steering column opening cover (1) and remove. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Shroud - Removal > Page 5310 3. Position the column tilt at the full-downward position. 4. Remove the two screws (4) attaching the upper shroud (1) to the lower shroud (2). After removing the screws, unclip the shrouds from each other by applying hand pressure along the seams where the shrouds connect on the sides, then remove the upper shroud. 5. Push the tilt lever (5) downward. 6. Remove the screw (3) attaching the lower shroud (2) to the steering column (6). Remove the lower shroud. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Shroud - Removal > Page 5311 Steering Column Cover: Service and Repair Steering Column Shroud - Installation Upper INSTALLATION 1. Position the column tilt at the full-downward position and lock it in place. 2. Install the upper shroud over the lower shroud, clipping the shrouds to one another. 3. Install the two screws (4) attaching the upper shroud (1) to the lower shroud (2). Lower INSTALLATION 1. Push the tilt lever (5) downward. 2. Install the lower shroud (2) over the tilt lever and onto the column. 3. Position the column tilt (5) at the full-upward position. 4. Push the tilt lever (5) upward, locking it in place. 5. Install the screw (3) attaching the lower shroud (2) to the steering column (6). 6. Position the column tilt at the full-downward position and lock it in place. 7. Install the upper shroud overthe lower shroud, clipping the shrouds to one another. 8. Install the two screws (4) attaching the upper shroud (1) to the lower shroud (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Shroud - Removal > Page 5312 9. Place the steering column opening cover (1) in place and seat the clips fully. 10. Install the two screws (2) and tighten until secure. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation Steering Gear: Description and Operation DESCRIPTION The steering gear (2) used is the rack-and-pinion type with power assist. It is mounted on the front suspension crossmember. The outer ends of the outer tie rods attach to the front (steering) knuckles. NOTE: The power steering gear should not be serviced or adjusted. If a malfunction or oil leak occurs with the steering gear, the complete steering gear needs to be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Page 5316 Steering Gear: Testing and Inspection POWER STEERING GEAR NOTE: This information is designed to be used in conjunction with the diagnostic charts at the beginning of the Steering section. See: Testing and Inspection OBJECTIONABLE HISS OR WHISTLE POSSIBLY CAUSED BY A NOISY STEERING GEAR 1. Check and adjust power steering fluid level in the reservoir as necessary. See: Service and Repair/Power Steering Fluid Level Checking 2. Start the vehicle and heat system by steering lock-to-lock 5 times with the engine running at 3000 rpm. Do not hold the gear against the stops for more than 5 seconds at a time. 3. Return the engine to idle speed. 4. Listen for the noise when turning the wheel slowly off center during a dry park maneuver. 5. Replace power steering gear if the hiss or whistle is present. See: Service and Repair/Steering Gear - Removal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal Steering Gear: Service and Repair Steering Gear - Removal STEERING GEAR NOTE: Before proceeding, See: Service Precautions . 1. Siphon out as much power steering fluid as possible from the pump. 2. Reposition the floor carpeting to access the intermediate shaft coupling at the base of the column. 3. Position the front wheels of vehicle in the STRAIGHT-AHEAD position, then turn the steering wheel to the right until the intermediate shaft coupling bolt (3) at the base of the column can be accessed. 4. Remove the intermediate shaft coupling bolt (3). Do not separate the intermediate shaft (2) from the steering gear pinion shaft (4) at this time. 5. Return the front wheels of vehicle (and steering wheel) to the STRAIGHT-AHEAD position. Using a steering wheel holder, lock the steering wheel in place to keep it from rotating. This keeps the clockspring in the proper orientation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 5319 6. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 7. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 8. On each side of the gear, remove the nut (2) from the out tie rod end (4) at the knuckle (3). 9. On each side of the gear, separate the tie rod end (3) from the knuckle (2) using Remover (1), Special Tool 9360. 10. If equipped, remove the engine belly pan. See: Body and Frame/Exterior Moulding / Trim/Underbody Cover/Service and Repair/Belly Pan Removal 11. Remove the rear engine mount. See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Engine Mount Insulator - Removal 12. Remove the front engine mount through-bolt. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 5320 13. Remove the three screws (1, 2) securing the heat shield (3) to the crossmember (4). Remove the shield. 14. Remove the return hose (1) at the steering gear (3). 15. Remove the pressure hose (2) at the steering gear (3). 16. Remove the fasteners (1) securing the power steering hose routing clamps (2) to the crossmember. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 5321 17. Remove the screws (1) securing the stabilizer bushing retainers (3) to the crossmember. 18. Remove the two stabilizer bushing retainers. NOTE: Before removing the front suspension crossmember from the vehicle, the location of the crossmember must be marked on the body of the vehicle. Do this so the crossmember can be relocated, upon reinstallation, against the body of vehicle in the same location as before removal. If the front suspension crossmember is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) may be lost. 19. Mark the location of the front crossmember on the body near each mounting bolt using a marker or crayon. Do not use a scratch awl or other tool that can penetrate the protective coating on the body. 20. Support the front crossmember with a transmission jack. 21. Remove the four mounting bolts (6) securing the front crossmember (1) to the body. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 5322 22. Lower the crossmember enough to access the intermediate shaft coupling (1) at the steering gear pinion shaft (4). Slide the coupling off the pinion shaft. 23. Remove the dash seals (3, 5) as necessary. 24. Remove the two bolts (1) securing the steering gear (2) to the crossmember. 25. Rotate the stabilizer bar up in order to remove the steering gear from the vehicle. 26. Remove the steering gear from the crossmember. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 5323 Steering Gear: Service and Repair Steering Gear - Installation STEERING GEAR 1. Rotate the stabilizer bar up and install the steering gear on the crossmember. 2. Install the two bolts (1) securing the steering gear (2) to the crossmember. Tighten the steering gear mounting bolts to 70 Nm (52 ft. lbs.). 3. Install the dash seals (3, 5) as necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 5324 4. Center the power steering gear rack in its travel as necessary. NOTE: When installing the front suspension crossmember (1) back in the vehicle, it is very important that the crossmember be attached to the body in exactly the same spot as when it was removed. Otherwise, the vehicle's wheel alignment settings (caster and camber) will be lost. 5. Slowly raise the crossmember (1) into mounted position using the transmission jack matching the crossmember to the marked locations on the body made during removal. 6. Check the positioning of the seals at the dash panel and adjust as necessary. 7. Install the four mounting bolts (6) securing the front crossmember (1) to the body. Tighten the crossmember mounting bolts to 150 Nm (111 ft. lbs.). 8. Remove the transmission jack. 9. Install the retainers (3) over the stabilizer bar cushions. Install all four stabilizer bar cushion retainer screws (1) and tighten them to 30 Nm (22 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 5325 10. Install the fasteners (1) securing the power steering hose routing clamps (2) to the crossmember. Use a NEW push clip or install screw (if so equipped) on the left and tighten screws to 8 Nm (71 in. lbs.). 11. Install the pressure hose (2) at the gear (3). Tighten the tube nut to 32 Nm (24 ft. lbs.). 12. Install the return hose (1) at the gear (3). Tighten the tube nut to 20 Nm (15 ft. lbs.). 13. Position the heat shield (3) and install the three screws (1, 2) securing the shield to the crossmember (4). Tighten the two front mounting screws (1) to 4 Nm (35 in. lbs.). Tighten the rear mounting screw (2) to 17 Nm (150 in. lbs.). 14. Install the front engine mount through-bolt. 15. Install the rear engine mount. See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Engine Mount Insulator - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 5326 16. If equipped, install the engine belly pan. See: Body and Frame/Exterior Moulding / Trim/Underbody Cover/Service and Repair/Belly Pan Installation. NOTE: Prior to attaching the outer tie rod end to the knuckle, inspect the tie rod seal boot. If the seal boot is damaged, replace the outer tie rod end. 17. On each side of the gear, install the outer tie rod end (4) into the hole in the knuckle arm (3). Start a NEW tie rod mounting nut (2) onto the stud. While holding the tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench. Tighten the nut to 132 Nm (97 ft. lbs.). 18. On each side of the vehicle, install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten the wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 19. Lower the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 5327 20. Remove the steering wheel holder. 21. Verify the front wheels of vehicle are in the STRAIGHT-AHEAD position. 22. Center the intermediate shaft (2) over the steering gear pinion shaft (4), lining up the ends, then slide the intermediate shaft onto the steering gear pinion shaft. 23. From center, rotate the steering wheel to the right approximately 90° or until the intermediate shaft coupling bolt (3) can be easily installed. 24. Install the intermediate shaft coupling bolt (3). Tighten the bolt to 42 Nm (31 ft. lbs.). 25. Reposition the floor carpet (1) in place. 26. Straighten the steering wheel to STRAIGHT-AHEAD position. 27. Fill and bleed the power steering system. See: Service and Repair/Power Steering System Bleeding 28. Check for fluid leaks. 29. Adjust front wheel toe as necessary. See: Alignment/Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 5331 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C1 (Instrument Panel) 4 Way Steering Mounted Controls Communication Module: Diagrams Steering Control Module C1 (Instrument Panel) 4 Way Connector C1 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C1 (Instrument Panel) 4 Way > Page 5334 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C2 (Instrument Panel) 6 Way Connector C2 - (INSTRUMENT PANEL) 6 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C1 (Instrument Panel) 4 Way > Page 5335 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C4 (Instrument Panel) 4 Way Connector C4 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation/Communication - Description. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 5338 Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 5339 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation/Communication - Description. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 5340 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. SCCM 1. Place the front road wheels in the STRAIGHT-AHEAD position. 2. Disconnect and isolate the negative battery cable. 3. Remove steering wheel See: Steering Wheel/Service and Repair/Removal. 4. Remove upper and lower steering column shrouds to gain access to the Steering Column Control Module (SCCM) (3) See: Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 5. Lock the clockspring rotor in the center position as follows: Insert a pin through the hole in the rotor at the 10 o'clock position. 6. Remove the three screws (1) to the SCCM. 7. Disconnect the electrical connectors (2) between the SCCM (1) and the instrument panel wiring harness at the base of the SCCM and remove from column. DISASSEMBLY NOTE: There is no need to disassemble the Steering Column Control Module (SCCM) if only removing the SCCM from the column. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 5343 1. Remove the left multi-function switch stalk retaining screw (2). 2. Pull the left stalk out of the SCCM. 3. Disconnect the left stalk electrical connector. 4. Separate the left switch from the SCCM. 5. Remove the one right multi-function switch retaining screw. 6. Pull right switch out of SCCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 5344 7. Disconnect the right switch electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 5345 Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Installation INSTALLATION NOTE: If SCCM is already assembled and needs to be installed, bypass ASSEMBLY and proceed with SCCM 1. ASSEMBLY 1. Connect the right stalk electrical connector. 2. Slide the right stalk into the groove and install the one retaining screw. 3. Connect the left stalk switch electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 5346 4. Install the left stalk switch retaining screw. SCCM 1. Position the SCCM (3) over the steering column shaft (2). 2. Install the three screws (1). 3. Connect the electrical connectors (2) to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged. 4. Install steering column shrouds See: Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. Be sure all wires are inside of shrouds. 5. Install steering wheel ensuring the flats on hub align with the clockspring See: Steering Wheel/Service and Repair/Installation. Pull the airbag leads through the larger slot. Ensure leads do not get pinched under the steering wheel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 5347 NOTE: There is a small wire harness in the steering wheel and it contains the horn circuits and speed control circuits. 6. Connect the speed control and horn wire connector into the clockspring. 7. Pull the grenade pin out of the clockspring. 8. Install the driver airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Installation WARNING: Do not connect the negative battery cable at this time. Perform the Air Bag System Test prior to connecting the negative battery cable See: Restraint Systems/Testing and Inspection . Failure to follow this warning may result in accidental air bag deployment and possible serious or fatal injury. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal Steering Wheel: Service and Repair Removal REMOVAL WARNING: Do not place a non-deployed airbag face down on a hard surface. The airbag will propel into the air if accidentally deployed. Failure to follow this instruction may result in possible serious or fatal injury. - Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. This will disable the airbag system. Failure to follow this instruction may result in accidental airbag deployment and possible serious or fatal injury. - Allow the airbag system capacitor to discharge for two minutes before removing the steering wheel or any airbag system component. Failure to follow this instruction may result in accidental airbag deployment and possible serious or fatal injury. 1. Adjust the steering wheel so that the tires are in the STRAIGHT-AHEAD position. 2. Disconnect and isolate the negative battery cable. 3. Remove the driver airbag (3) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Removal. 4. Disconnect the wiring connector (2) at the clockspring. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal > Page 5352 5. While holding the steering wheel (2) firmly in place, remove the bolt (4) that secures the steering wheel to the steering column shaft (1). CAUTION: Do not bump or hammer on the steering wheel or steering column shaft when removing the steering wheel. 6. Install an appropriate wheel puller with hooked legs (1) on the steering wheel over the steering shaft. CAUTION: Do not attempt to rotate the clockspring rotor once the steering wheel is removed. The clockspring must remain centered in its travel to avoid overextending the clockspring inner parts, causing the clockspring to become inoperative. If removed and handled properly using the correct procedures, it should remain in the "centered" position. If there is any question as to whether the clockspring is in the "centered" position of travel, perform the clockspring centering procedure before installing the steering wheel See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Procedures . 7. While holding the steering wheel firmly in the STRAIGHT-AHEAD position, remove the steering wheel from the steering column shaft splines using the wheel puller. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal > Page 5353 Steering Wheel: Service and Repair Installation INSTALLATION 1. Confirm that: a. The front wheels are in the STRAIGHT-AHEAD position. b. The turn signal stalk is in the NEUTRAL position. CAUTION: Do not install the steering wheel onto the shaft of the steering column by driving it onto the shaft. 2. Align the wide mounting spline of the steering wheel (2) with the missing spline area of the steering column shaft (1) and push the wheel onto the shaft. Make sure the clockspring lines up with the back of the wheel and does not bind. 3. Install the steering wheel retaining bolt (4). Tighten the steering wheel retaining bolt to 50 Nm (37 ft. lbs.). 4. Connect the wiring connector (2) at the clockspring. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal > Page 5354 5. Install the driver airbag (3) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Installation. WARNING: Do not reconnect the battery without first performing the Airbag System Test procedure See: Restraint Systems/Testing and Inspection . Failure to perform the Airbag System Test may result in accidental airbag deployment and serious or fatal injury. 6. Reconnect the battery using the Airbag System Test procedure See: Restraint Systems/Testing and Inspection. 7. Verify vehicle and system operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection Tie Rod End: Testing and Inspection TIE ROD Tie rod free-play can be measured using the following hand methods: OUTER TIE ROD 1. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair. 2. Remove the front wheels. See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Removal. 3. Install two standard wheel mounting nuts, flat side to rotor, diagonally opposite to each on the rotor. 4. Attach a magnetic dial indicator (2) to the inside or outside of the brake rotor, then align the dial indicator's contact pointer (1) with the direction of the stud axis and touch the outer tie rod. 5. Zero the dial indicator. (3) NOTE: When checking free-play, DO NOT rotate the tie rod. Just because a tie rod rotates easily does not mean that it is necessarily faulty. Using more than light hand pressure will result in a false reading. 6. Grasp the outer tie rod near the ball stud and attempt to move the tie rod straight up and down using light hand pressure. (Less than 10 lbs. of force.) 7. Measure and record any tie rod free-play movement. 8. Remove the magnetic dial indicator. 9. Remove the standard wheel mounting nuts from the two studs. If the free-play in the tie rod exceeds 0.05 mm (.002 in.), replace the outer tie rod. See: Service and Repair/Tie Rod End - Removal. If the free-play is less than 0.05 mm (.002 in.) at the outer tie rod check the inner tie rod for free-play. Refer to the following procedure. INNER TIE ROD Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Page 5359 NOTE: Always check and repair (if necessary) outer tie rod free-play before checking inner tie rod free-play. False results can otherwise be obtained. 1. Grasp the inner tie rod near the steering gear bellows and attempt to move the tie rod straight up and down. If any free-play is felt, replace the inner tie rod See: Service and Repair/Tie Rod End - Removal. 2. If no free-play is felt, install the front wheels. See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation 3. Remove support and lower the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Tie Rod End - Removal Tie Rod End: Service and Repair Tie Rod End - Removal Inner Tie Rod INNER TIE ROD 1. Remove the outer tie rod. See: 2. Remove the tie rod jam nut from the inner tie rod. 3. Remove the clamp (3) securing the bellows (1) to the inner tie rod. 4. Remove the clamp (2) securing the bellows (1) to the steering gear body. 5. Remove the bellows. 6. Remove the travel restrictor (3) from the inner tie rod (1). 7. Install an appropriate inner tie rod removal tool on the inner tie rod (1) hex. CAUTION: If the inner tie rod cannot be removed using the specified tools, do not use a hammer or heat to loosen. Damage to the steering gear will occur. Replace the entire steering gear. 8. Unthread and remove the inner tie rod (1) from the steering gear (2). Outer Tie Rod End OUTER TIE ROD END Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Tie Rod End - Removal > Page 5362 1. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3) , then the tire and wheel assembly (1). 3. Loosen the tie rod jam nut (5). 4. Remove the nut (2) attaching the outer tie rod (4) to the knuckle (3). To do this, hold the tie rod end stud with a wrench while loosening and removing the nut with a standard wrench or crowfoot wrench. 5. Release the tie rod end (3) from the knuckle (2) using Remover, Special Tool 9360 (1) 6. Remove the outer tie rod (3) from the knuckle (2). NOTE: When unscrewing the outer tie rod from inner, count the number of revolutions to take it off. This action will aid in installation, getting the toe close to where it needs to be when setting the wheel alignment. 7. Remove the outer tie rod from the inner tie rod. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Tie Rod End - Removal > Page 5363 Tie Rod End: Service and Repair Tie Rod End - Installation Inner Tie Rod INNER TIE ROD CAUTION: When installing the travel restrictor, be sure to use the same color and thickness travel restrictor as was removed. This action is necessary to properly set gear travel for the steering gear being serviced. Travel restrictor thickness can vary side-to-side on the steering gear. 1. Install the travel restrictor (1), flat side of teeth (2) facing out, on the inboard end of the inner tie rod ball joint. 2. Apply Mopar(R) Lock & Seal Adhesive or equivalent medium thread locker adhesive to the inboard end threads of the inner tie rod. 3. Install the inner tie rod (1) onto the gear (2) using an appropriate inner tie rod installation tool or crows foot wrench on the hex. Tighten the inner tie rod to 78 Nm, (58 ft. lbs.). 4. Loosely place a NEW clamp over the large end of the NEW bellows. 5. Slide the NEW bellows with clamp over the end of the inner tie rod and onto the gear body. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Tie Rod End - Removal > Page 5364 6. Push the small end of the bellows (2) past the groove (1) machined into the inner tie rod. 7. Apply a small amount of Mopar(R) Lubriplate or equivalent uniformly to the groove (1) in the inner tie rod shaft. This allows for toe adjustment without twisting the bellows. 8. Pull the small end of the bellows outward until the ridge inside the bellows engages the groove. 9. Install a NEW clamp (3) over the small end of the bellows (1). 10. Using crimping pliers (1), crimp the large clamp (2) securing the bellows to the gear body. 11. Thread the tie rod jam nut onto the inner tie rod far enough to install the outer tie rod. 12. Install the outer tie rod. See: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Tie Rod End - Removal > Page 5365 Outer Tie Rod End OUTER TIE ROD END 1. If it is not already installed, install the jam nut (5) on the inner tie rod threads. Thread the nut down the inner tie rod far enough to allow for outer tie rod installation. 2. Thread the outer tie rod (4) onto the inner tie rod approximately the same amount of revolutions as the original was installed. 3. Snug the tie rod jam nut (5) just enough to hold the tie rods in place. Do not tighten the jam nut at this time. 4. Install the outer tie rod ball stud into the hole in the knuckle arm (3). Start a NEW tie rod mounting nut (2) onto the stud. While holding the tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench. Tighten the nut to 132 Nm (97 ft. lbs.). 5. Install the tire and wheel assembly (1)See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Adjust the front wheel toe setting. See: Alignment/Service and Repair. 8. Tighten the tie rod jam nut to 75 Nm (55 ft. lbs.) once wheel toe is set. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications BALL JOINT The end play is acceptable if no more than 0.8 mm (0.031 in.) of end play is achieved back-to-back Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 5370 Ball Joint: Description and Operation DESCRIPTION The lower ball joint is not serviced separately from the control arm on this vehicle. If it is determined from the Diagnosis and Testing procedure that the ball joint is out of specification, the entire lower control arm must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Page 5371 Ball Joint: Testing and Inspection LOWER BALL JOINT 1. Raise the vehicle allowing the front suspension to hang. 2. Remove the tire and wheel assembly. 3. Using Dial Indicator C-3339A, or equivalent, attach the dial indicator mount to the knuckle and align the dial indicator's plunger with the direction of the stud axis, touching the end of the ball joint stud in the lower control arm. 4. Push up on the lower control arm and zero the dial indicator. NOTE: Use care when applying load to the knuckle as to avoid damaging the ball joint seal boot. 5. From the front of the vehicle, insert a pry bar between the knuckle and lower control arm, resting it on the lower control arm. Use lever principle to push the knuckle up from the lower control arm. Apply the load until the needle of the dial indicator no longer moves. 6. Record the ball joint movement. The end play is acceptable if no more than 0.8 mm (0.031 in.) of end play is achieved back-to-back. 7. Perform this procedure on each side of the vehicle as necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Lower Ball Joint Boot Seal - Removal Ball Joint: Service and Repair Front Suspension Lower Ball Joint Boot Seal - Removal REMOVAL CAUTION: This procedure is designed to be used only if a seal boot is damaged during related service procedures. It is not to be used as a repair procedure for a cut seal boot on a vehicle that has been driven and exposed to road and weather conditions. 1. Remove the lower control arm from the vehicle. See: Control Arm/Service and Repair/Front Lower Control Arm - Removal 2. Using a screwdriver or other suitable tool (2), pry the seal boot (1) off of the ball joint. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Lower Ball Joint Boot Seal - Removal > Page 5374 Ball Joint: Service and Repair Front Suspension Lower Ball Joint Boot Seal - Installation INSTALLATION CAUTION: This procedure is designed to be used only if a seal boot is damaged during related service procedures. It is not to be used as a repair procedure for a cut seal boot on a vehicle that has been driven and exposed to road and weather conditions. 1. Place a liberal dab of Mopar(R) Multi-Mileage Lube (No more than 10g) or equivalent around the base of the ball joint stud at the socket. 2. Position the ball joint stud straight up. 3. Place the NEW ball joint seal boot over the ball joint stud. 4. By hand, start the seal boot over the sides of the ball joint. CAUTION: Prior to installing the sealing boot using Remover/Installer 6289-4, make sure there are no burrs on the inside of the tool. Remove any burrs and lubricate with a small amount of Mopar(R) Multi-Mileage Lube or equivalent. 5. Place Remover/Installer 6289-4 onto the screw-drive of Ball Joint Press C-4212F. 6. Place Remover/Installer 6289-6, angle-cut end up into the cup of Ball Joint Press C-4212F. Before tightening the set, turn the Remover/Installer so that the tallest point of the angle-cut is away from the body of the control arm when installing the seal boot. 7. Place the control arm ball joint into Remover/Installer 6289-6. Rotate the arm left or right until the tallest point of the angle cut on the Remover/Installer is away from the body of the control arm. 8. Lower Remover/Installer 6289-4 onto outer lip of ball joint seal. 9. By hand, tighten the Ball Joint Press screw-drive installing the seal boot. Tighten the screw-drive until the seal boot is seated squarely down against the top surface of the lower control arm (3). It may be necessary to use a wrench to seat the seal boot, but do not overtighten. 10. Remove the tools and wipe any grease off the ball joint stud using a clean shop towel with Mopar(R) Brake Parts Cleaner applied to it. 11. Install the lower control arm. See: Control Arm/Service and Repair/Front Lower Control Arm - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Testing and Inspection Control Arm: Testing and Inspection LOWER CONTROL ARM Inspect the lower control arm for signs of damage from contact with the ground or road debris. If the lower control arm shows any sign of damage, look for distortion. Do not attempt to repair or straighten a broken or bent lower control arm. If damaged, the lower control arm stamping is serviced only as a complete component. Inspect both lower control arm isolator bushings for severe deterioration and replace the lower control arm as required. Inspect the ball joint per the inspection procedure and replace the lower control arm required. The only serviceable component of the lower control arm is the ball joint seal boot. It should only be replaced if damaged during service of a chassis component. Otherwise, replace the entire control arm. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal Control Arm: Service and Repair Front Lower Control Arm - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information . 1. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the nut (5) and pinch bolt (4) clamping the ball joint (6) stud to the knuckle (3). CAUTION: Upon removing the knuckle from the ball joint stud, do not pull outward on the knuckle. Pulling the knuckle outward at this point Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 5380 can separate the inner C/V joint on the halfshaft thus damaging it. CAUTION: Use care when separating the ball joint stud (4) from the knuckle (1), so the ball joint seal does not get cut. 4. Using an appropriate prying tool (2), separate the ball joint stud (4) from the knuckle (1) by prying down on lower control arm (3) and up against the ball joint boss on the knuckle. 5. Remove the front bolt (2) attaching the lower control arm (3) to the front suspension crossmember (4). 6. Remove the nut (1) on the rear bolt attaching the lower control arm (3) to the front suspension crossmember (4). Remove the bolt. 7. Remove the lower control arm (3) from the crossmember (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 5381 Control Arm: Service and Repair Front Lower Control Arm - Installation INSTALLATION 1. Place the lower control arm (2) into the front suspension crossmember (1). 2. Insert the rear bolt (3) up through the crossmember (1) and lower control arm (2). 3. Install, but do not fully tighten, the nut (1) on the rear bolt attaching the lower control arm (3) to the crossmember (4). 4. Install, but do not fully tighten, the front bolt (2) attaching the lower control arm to the crossmember. 5. With no weight or obstruction on the lower control arm, tighten the lower control arm rear mounting bolt nut (1) to 183 Nm (135 ft. lbs.). 6. With no weight or obstruction on the lower control arm, tighten the lower control arm front pivot bolt (2) to the following: - 135 Nm (100 ft. lbs.) (Vehicles built up to 8/1/08) - 160 Nm (118 ft. lbs.) (Vehicles built after 8/1/08) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 5382 7. Install the ball joint (6) stud into the knuckle (3), aligning the bolt hole in the knuckle boss with the groove formed in the side of the ball joint stud. 8. Install a NEW ball joint stud pinch bolt (4) and nut (5). Tighten the nut to 82 Nm (60 ft. lbs.). 9. Install tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 10. Lower the vehicle. 11. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 5383 Control Arm: Service and Repair Rear Upper Control Arm - Removal REMOVAL 1. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the nut (4) and bolt (3) securing the upper control arm (1) to the trailing link. 4. Remove the bolt (2) securing the upper control arm (1) to the crossmember. 5. Remove the upper control arm (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 5384 Control Arm: Service and Repair Rear Upper Control Arm - Installation INSTALLATION 1. Position the upper control arm (1) and install the bolt (2) securing the arm to the crossmember. Do not tighten at this time. 2. Install the bolt (3) and nut (4) securing the upper control arm (1) to the trailing link. Do not tighten at this time. 3. Install tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 4. Lower the vehicle. 5. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as necessary to access mounting bolts and nuts. 6. Tighten the upper control arm mounting bolt at the crossmember to 95 Nm (70 ft. lbs.). 7. Tighten the upper control arm mounting bolt nut at the trailing link to 95 Nm (70 ft. lbs.). 8. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 5385 Control Arm: Service and Repair Front Lower Control Arm - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information . 1. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the nut (5) and pinch bolt (4) clamping the ball joint (6) stud to the knuckle (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 5386 CAUTION: Upon removing the knuckle from the ball joint stud, do not pull outward on the knuckle. Pulling the knuckle outward at this point can separate the inner C/V joint on the halfshaft thus damaging it. CAUTION: Use care when separating the ball joint stud (4) from the knuckle (1), so the ball joint seal does not get cut. 4. Using an appropriate prying tool (2), separate the ball joint stud (4) from the knuckle (1) by prying down on lower control arm (3) and up against the ball joint boss on the knuckle. 5. Remove the front bolt (2) attaching the lower control arm (3) to the front suspension crossmember (4). 6. Remove the nut (1) on the rear bolt attaching the lower control arm (3) to the front suspension crossmember (4). Remove the bolt. 7. Remove the lower control arm (3) from the crossmember (4). Front Lower Control Arm - Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 5387 1. Place the lower control arm (2) into the front suspension crossmember (1). 2. Insert the rear bolt (3) up through the crossmember (1) and lower control arm (2). 3. Install, but do not fully tighten, the nut (1) on the rear bolt attaching the lower control arm (3) to the crossmember (4). 4. Install, but do not fully tighten, the front bolt (2) attaching the lower control arm to the crossmember. 5. With no weight or obstruction on the lower control arm, tighten the lower control arm rear mounting bolt nut (1) to 183 Nm (135 ft. lbs.). 6. With no weight or obstruction on the lower control arm, tighten the lower control arm front pivot bolt (2) to the following: - 135 Nm (100 ft. lbs.) (Vehicles built up to 8/1/08) - 160 Nm (118 ft. lbs.) (Vehicles built after 8/1/08) 7. Install the ball joint (6) stud into the knuckle (3), aligning the bolt hole in the knuckle boss with the groove formed in the side of the ball joint stud. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 5388 8. Install a NEW ball joint stud pinch bolt (4) and nut (5). Tighten the nut to 82 Nm (60 ft. lbs.). 9. Install tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 10. Lower the vehicle. 11. Perform wheel alignment as necessary. See: Alignment/Service and Repair Rear Upper Control Arm - Removal REMOVAL 1. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 5389 3. Remove the nut (4) and bolt (3) securing the upper control arm (1) to the trailing link. 4. Remove the bolt (2) securing the upper control arm (1) to the crossmember. 5. Remove the upper control arm (1). Rear Upper Control Arm - Installation INSTALLATION 1. Position the upper control arm (1) and install the bolt (2) securing the arm to the crossmember. Do not tighten at this time. 2. Install the bolt (3) and nut (4) securing the upper control arm (1) to the trailing link. Do not tighten at this time. 3. Install tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 5390 4. Lower the vehicle. 5. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as necessary to access mounting bolts and nuts. 6. Tighten the upper control arm mounting bolt at the crossmember to 95 Nm (70 ft. lbs.). 7. Tighten the upper control arm mounting bolt nut at the trailing link to 95 Nm (70 ft. lbs.). 8. Perform wheel alignment as necessary. See: Alignment/Service and Repair Rear Lower Control Arm - Removal REMOVAL 1. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. If equipped, while holding the stabilizer bar link lower stud stationary, remove the nut (2) securing the link to the lower control arm (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 5391 4. Remove the lower shock mounting nut (3) and bolt (1). 5. Remove the stay brace (3) mounting screws (2). Remove the stay brace. 6. Remove the nut (2) and bolt (3) securing the lower control arm (4) to the trailing link (1). 7. Remove the nut (6) and bolt (5) securing the lower control arm (4) to the crossmember (7). 8. Remove the lower control arm (4). Rear Lower Control Arm - Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 5392 1. Position the lower control arm and install the bolt (5) and nut (6) securing the lower control arm (4) to the crossmember (7). Do not tighten at this time. 2. Install the bolt (3) and nut (2) securing the lower control arm (4) to the trailing link (1). Do not tighten at this time. 3. Install the stay brace (3) on the crossmember (1). Install and tighten the mounting screws (2) to 25 Nm (18 ft. lbs.). 4. Install the mounting bolt (1) and nut (3) fastening the shock assembly (2) to the lower control arm (4). Do not tighten at this time. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Lower Control Arm - Removal > Page 5393 NOTE: When attaching a stabilizer bar link to the lower control arm it is important that the lower mounting stud be positioned properly. The lower mounting stud on the right side link needs to point toward the rear of the vehicle when inserted through the lower control arm mounting flange. The left side link lower stud needs to point toward the front of the vehicle. Otherwise the suspension geometry will not function properly. 5. If equipped, attach the stabilizer bar link to the lower control arm (4). Install the nut (2) and while holding the stabilizer bar link lower stud stationary, tighten the nut (2) to 58 Nm (43 ft. lbs.). 6. Install tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 7. Lower the vehicle. 8. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as necessary to access mounting bolts and nuts. 9. Tighten the lower control arm mounting bolt nut at the crossmember to 95 Nm (70 ft. lbs.). 10. Tighten the lower control arm mounting bolt nut at the trailing link to 95 Nm (70 ft. lbs.). 11. Tighten the shock assembly lower mounting bolt nut to 99 Nm (73 ft. lbs.). 12. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal Cross-Member: Service and Repair Crossmember - Removal Front Fore and Aft REMOVAL 1. Raise and support the vehicle, See: Wheels and Tires/Vehicle Lifting/Service and Repair. 2. Remove the four wheel well screws. 3. If equipped, remove the three front screws (4), the three rear screws (2) and one push pin fastener from the center of the belly pan. 4. Remove the crossmember bolts (1, 2 and 3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5398 5. Remove the engine roll mount (3) through bolt (2) and remove the fore/aft crossmember (4). Front Suspension REMOVAL 1. Raise and support the vehicle, See: Wheels and Tires/Vehicle Lifting/Service and Repair. 2. Remove the four wheel well screws. 3. If equipped, remove the three front screws (4), the three rear screws (2) and one push pin fastener from the center of the belly pan. 4. Remove the rear roll mount (4) through bolt (2). 5. Remove the three bolts (3) attaching the rear roll mount (5) to the crossmember and remove the mount. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5399 6. Remove the for/aft crossmember (4) See: . 7. Remove the front wheels (1), See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Removal. 8. Remove the lower ball joint (6) pinch bolts (4) and nuts (5). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5400 9. Remove the bolt attaching the pressure line routing bracket to the steering gear. 10. Remove the bolt attaching the return line to the crossmember. 11. Remove the sway bar bushing bolts (1) and support the sway bar (2) up in the vehicle. 12. Remove the steering gear mounting bolts (1) and support the steering gear (2) up in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5401 13. Mark the crossmember (3) to body location (1) using a grease pencil (2) or equivalent. 14. Support the crossmember with a suitable lifting device. 15. Remove the crossmember bolts (1 and 2) and lower the crossmember from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5402 16. Remove the lower control arm (3) front pivot bolts (2). 17. Remove the lower control arm rear pivot bolts (3) and separate the lower control arms from the crossmember (1). Rear Suspension REMOVAL 1. Remove the park brake shoes See: Brakes and Traction Control/Parking Brake System/Parking Brake Shoe/Service and Repair/Removal. 2. Remove the park brake cable from lever. 3. Remove the hair pin clip and separate the brake cable (2) from the backing plate (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5403 4. Remove the bolt (2) and separate the brake line (1) from the trailing arm (3). 5. Remove the bolt (1), the clip (2) and separate the brake line (3) from the trailing arm. 6. Separate the wheel speed sensors and position aside as necessary to remove the crossmember, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Wheel Speed Sensor Removal/Rear 7. Remove the lower strut bolts. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5404 8. Remove the trailing link bushing bolts. 9. Support the rear cradle with a suitable lifting device. 10. Remove the rear cradle bolts and lower the cradle assembly from vehicle. 11. Remove the lower stabilizer link nuts (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5405 12. Remove the lower link bolts (5 and 6) at the cradle. 13. Remove the upper link bolts (2) at the cradle. 14. Remove the toe link cam bolts (1) at the cradle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5406 15. Remove the suspension knuckle assemblies. 16. Remove the stabilizer bushing bolts (1) and separate the stabilizer bar from the cradle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5407 Cross-Member: Service and Repair Crossmember - Installation Front Fore and Aft INSTALLATION 1. Install the fore/aft crossmember and install the engine anti-roll mount (3) through bolt (2). 2. Install the bolts (1, 2 and 3), and tighten using the following sequence: a. Tighten the bolt (1) to 78 Nm (58 ft. lbs.). b. Tighten the bolt (2) to 78 Nm (58 ft. lbs.). c. Tighten the bolt (3) to 129 Nm (95 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5408 3. Tighten the bolt (2) to 65 Nm (48 ft. lbs.). 4. If equipped, install the belly pan. 5. Install the three front screws (4), the three rear screws (2) and on push pin fastener into the center of the belly pan. Front Suspension INSTALLATION 1. Install the lower control arms and install the rear pivot bolts (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5409 2. Install the front pivot bolts (2). If built before 8/1/08, tighten to 135 N-m (100 ft. lbs.). If built after 8/1/08, tighten to 160 N-m (118 ft. lbs.). 3. Support the crossmember on a suitable lifting device. 4. Raise the crossmember into position onto the vehicle. 5. Install the bolts (1 and 2) and align the engine cradle to the marks made during removal. 6. Tighten the bolts to 150 Nm (111 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5410 7. Position the steering gear back into place and install the bolts (1). 8. Tighten the bolts to 70 Nm (52 ft. lbs.). 9. Position the stabilizer bar (2) back into place and install the bushing bolts (1). 10. Tighten the bolts to 61 Nm (45 ft. lbs.). 11. Position the power steering lines back into place and install the support bracket (2) bolts (1). 12. Tighten the bolts to 8 Nm (70 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5411 13. Connect the lower ball joint stud (6) to the knuckle (3). 14. Install a NEW ball joint stud pinch bolt (4) and nut (5). Tighten the nut to 82 Nm (60 ft. lbs.). 15. Install the fore/aft crossmember (4), See: 16. Install the front wheels (1), See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation 17. With the full weight of the vehicle on the suspension tighten the front control arm bushing bolts to 123 Nm (91 ft. lbs.) 18. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5412 19. Install the rear roll mount (4) and install the three bolts (3) attaching it to the crossmember. 20. Tighten the bolts (3) to 153 Nm (112 ft. lbs.). 21. Install the through bolt (2) and tighten to 65 Nm (48 ft. lbs.). 22. If equipped, install the belly pan. 23. Install the three front screws (4), the three rear screws (2) and push pin fasteners into the center of the belly pan. Rear Suspension INSTALLATION 1. Install the stabilizer bar and install the bushings and bolts (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5413 2. Tighten the bolts to 61 Nm (45 ft. lbs.). 3. Position the suspension knuckle assemblies back into position onto the crossmember. 4. Install the toe link cam bolts (1) at the cradle. 5. Tighten the bolts to 35 Nm (26 ft. lbs.). 6. Install the upper link bolts (2) at the cradle. 7. Tighten the bolts to 90 Nm (70 ft. lbs.). 8. Install the lower link bolts (5 and 6) at the cradle. 9. Tighten the bolts to 90 Nm (70 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5414 10. Install the stabilizer link nuts (2). 11. Tighten the nuts to 58 Nm (43 ft. lbs.). 12. Support the rear cradle assembly (1) with a suitable lifting device and position back into the vehicle. 13. Install the cradle bolts (2 and 3): a. Tighten the front bolt (2) first to 110 Nm (81 ft. lbs.). b. Tighten the rear bolt (3) next to 110 Nm (81 ft. lbs.). 14. Install the trailing link (1) bushing bolts (2 and 3): a. Tighten the inboard bolt (3) first to 110 Nm (81 ft. lbs.). b. Tighten the outboard bolt (2) next to 110 Nm (81 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5415 15. Install the lower strut bolts (1). 16. Tighten the bolts to 99 Nm 73 ft. lbs.). 17. Install the wheel speed sensor back, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Wheel Speed Sensor - Installation/Rear. 18. Position the brake lines (3) back into place, connect the clips (2) and install the bolts (1). 19. Tighten the bolts to 15 Nm (11 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 5416 20. Position the brake lines (1) back into place, and install the bolts (2). 21. Tighten the bolts to 23 Nm (17 ft. lbs.). 22. Install the brake cable (2) onto the backing plate (3) and install the hair pin clip (1). 23. Connect the brake cable to the park brake lever. 24. Install the park brake shoes, See: Brakes and Traction Control/Parking Brake System/Parking Brake Shoe/Service and Repair/Installation. 25. Check and adjust wheel alignment as necessary, See: Alignment/Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation DESCRIPTION The knuckle (1) is a single casting with legs machined for attachment to the front strut assembly on the top, lower control arm ball joint on the bottom, and steering linkage on the trailing end. The knuckle also has two machined, drilled and tapped legs on the leading end casting to support and align the front disc brake caliper adapter. The knuckle supports the wheel bearing (5) and hub (3). The hub is pressed into a sealed-for-life wheel bearing that is pressed into the knuckle. A snap ring also holds the bearing in place. A shield is pressed onto the knuckle behind the hub. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation > Page 5420 Front Steering Knuckle: Testing and Inspection KNUCKLE The front suspension knuckle is not a repairable component of the front suspension. It must be replaced if found to be damaged in any way. If it is determined that the knuckle is bent when servicing the vehicle, no attempt is to be made to straighten the knuckle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal Front Steering Knuckle: Service and Repair Front Steering Knuckle - Removal REMOVAL NOTE: Before proceeding, review all Warnings and Cautions. See: Service Precautions/Technician Safety Information 1. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove cotter pin (1), lock (7) and spring washer (2) from halfshaft stub shaft (5). 4. While a helper applies the brakes to keep the hub (1) from rotating, remove the hub nut (3) and washer (6). 5. Access and remove the front brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 5423 6. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (4). 7. Remove the screw (2) fastening the wheel speed sensor head (3) to the knuckle (4). Pull the sensor head out of the knuckle. 8. Remove the nut (2) attaching the outer tie rod (7) to the knuckle (3). To do this, hold the tie rod end stud with a wrench while loosening and removing the nut with a standard wrench or crowfoot wrench. 9. Release the outer tie rod end (3) from the knuckle (2) using Remover 9360 (1). 10. Remove the outer tie rod from the knuckle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 5424 11. Remove the nut (5) and pinch bolt (4) clamping the ball joint stud (6) to the knuckle (3). CAUTION: The strut assembly-to-knuckle attaching bolts (5) are serrated and must not be turned during removal. Proper removal is required. Refer to the following steps for the correct method. 12. While holding the bolt heads stationary, remove the two nuts (2) from the bolts (5) attaching the strut (3) to the knuckle (6). 13. Remove the two bolts (5) attaching the strut (3) to the knuckle (6) using a pin punch. CAUTION: Use care when separating the ball joint stud (4) from the knuckle (1), so the ball joint seal does not get cut. 14. Using an appropriate prying tool (2), separate the ball joint stud (4) from the knuckle (1) by prying down on lower control arm (3) and up against the ball joint boss on the knuckle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 5425 NOTE: Do not allow the half shaft (1) to hang by the inner C/V joint; it must be supported to keep the joint from separating during this operation. 15. Pull the knuckle (3) off the half shaft (1) outer C/V joint splines and remove the knuckle from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 5426 Front Steering Knuckle: Service and Repair Front Steering Knuckle - Installation INSTALLATION 1. Slide the hub of the knuckle (3) onto the splines of the halfshaft outer C/V joint (1). 2. Install the knuckle (3) onto the ball joint (6) stud aligning the bolt hole in the knuckle boss with the groove formed into the side of the ball joint stud. 3. Install a NEW ball joint stud pinch bolt (4) and nut (5). Tighten the nut to 82 Nm (60 ft. lbs.). CAUTION: The strut assembly-to-knuckle attaching bolts (2) are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the steering knuckle. Refer to the following step. 4. Position the lower end of the strut assembly (3) in line with the upper end of the knuckle (6), aligning the mounting holes. Install the two mounting bolts (5). 5. Install the nuts (2) on the two bolts (5). While holding the bolts in place, tighten the nuts to 110 Nm (81 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 5427 6. Install the outer tie rod (7) ball stud into the hole in the knuckle (3) arm. Start the tie rod end-to-knuckle nut (2) onto the stud. While holding the tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench to 132 Nm (97 ft. lbs.). 7. Install the wheel speed sensor head (3) into the knuckle (4). Install the mounting screw (2) and tighten it to 12 Nm (106 in. lbs.). 8. Install the routing clip (1) securing the wheel speed sensor cable to the knuckle (4). 9. Install the brake rotor, disc brake caliper and adapter. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation 10. Clean all foreign matter from the threads of the halfshaft stub shaft. 11. Install the washer (6) and hub nut (3) on end of halfshaft stub shaft (5). While a helper applies the brakes to keep the hub (4) from rotating, tighten the hub nut to 244 Nm (180 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 5428 12. Install the spring washer (2) and hub nut lock (7) over the hub nut and stub shaft. Install a NEW cotter pin (1) securing nut lock in place and wrap the cotter pin prongs tightly around the nut lock. 13. Install tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 14. Lower the vehicle. NOTE: If the original knuckle is being reinstalled, wheel alignment may not be necessary due to Net-Build design. 15. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair > Rear Toe Link - Removal Rear Knuckle Alignment Link: Service and Repair Rear Toe Link - Removal REMOVAL 1. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 2. Remove the bolt (2) securing the toe link (3) to the trailing link. 3. Mark the position of the cam bolt cam on the crossmember using a paint marker or crayon. This mark will be used upon installation to help get the alignment close prior to performing rear wheel alignment. Do not use any type marker that will scratch or damage the surface of the crossmember. 4. While holding the cam bolt head (3) stationary, loosen and remove the toe link mounting cam bolt nut (1) and washer. Remove the cam bolt. 5. Remove the toe link (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair > Rear Toe Link - Removal > Page 5433 Rear Knuckle Alignment Link: Service and Repair Rear Toe Link - Installation INSTALLATION CAUTION: When installing the cam bolt (3) and washer make sure the cams stay inside the abutments built into the crossmember. Failure to do so can damage the abutments and make toe adjustment difficult. 1. Position the toe link (2) and install the cam bolt (3) from the front through the crossmember and link. Match the cam on the bolt to the marks made during removal or position the top of the cam to the 12 O'clock position. 2. Install the cam washer and nut (1) securing the toe link (2) to the crossmember. Do not tighten at this time. 3. Install the bolt (2) securing the link to the trailing link. To install the bolt it may be necessary to flex the trailing link body mount bushing inward or outward using an appropriate prying tool. Do not tighten at this time. 4. Lower the vehicle. 5. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as necessary to access mounting bolts and nuts. 6. Tighten the toe link mounting bolt at the trailing link to 95 Nm (70 ft. lbs.). 7. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair > Rear Toe Link - Removal > Page 5434 8. Once rear toe is set, while holding the cam bolt head (3) stationary, tighten the toe link mounting cam bolt nut (1) to 35 Nm (26 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar - Removal Stabilizer Bar: Service and Repair Front Stabilizer Bar - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information . 1. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 2. If equipped, remove the engine belly pan. See: Body and Frame/Exterior Moulding / Trim/Underbody Cover/Service and Repair/Belly Pan Removal 3. Remove the rear engine mount. See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Engine Mount Insulator - Removal. 4. Remove the front engine mount through-bolt. 5. Remove the fasteners (1) securing the power steering hose routing clamps (2) to the crossmember. 6. At each end of the stabilizer bar, while holding the stabilizer bar link (1) lower stud stationary, remove the nut (3) securing the link to the stabilizer bar (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar - Removal > Page 5439 7. Remove the screws (1) securing the stabilizer bushing retainers (3) to the crossmember. 8. Remove the two stabilizer bushing retainers. 9. Utilizing the slit cut into the cushions (bushings), remove the two cushions from the stabilizer bar. NOTE: Before removing the front suspension crossmember from the vehicle, the location of the crossmember must be marked on the body of the vehicle. Do this so the crossmember can be relocated, upon reinstallation, against the body of vehicle in the same location as before removal. If the front suspension crossmember is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) may be lost. 10. Mark the location of the front crossmember on the body near each mounting bolt. 11. Support the crossmember with a transmission jack. 12. Remove the four mounting bolts (6) securing the front crossmember (1) to the body. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar - Removal > Page 5440 13. Remove the two bolts (1) securing the steering gear (2) to the crossmember. 14. Support the steering gear using a bungee cord or other to keep the steering gear from lowering when the crossmember is lowered. 15. Slowly lower the crossmember until there is enough space present to remove the stabilizer bar between the rear of the crossmember and the body. Due to the fact that the fore-and-aft crossmember is still attached, do not lower crossmember any more than necessary to remove the stabilizer bar. 16. Remove the stabilizer bar out over rear of crossmember. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar - Removal > Page 5441 Stabilizer Bar: Service and Repair Front Stabilizer Bar - Installation INSTALLATION NOTE: Before stabilizer bar installation, inspect the cushions and links for excessive wear, cracks, damage and distortion. Replace any pieces failing inspection. NOTE: Before installing the stabilizer bar, make sure the bar is not upside down. The stabilizer bar (1) must be installed so that when in mounted position, the ends of the bar curve over the top of the steering gear before attaching to the links. 1. Install the stabilizer bar, link ends first, from the rear over top of the crossmember. Curve the ends of the bar over the steering gear. 2. Slowly raise the crossmember (1) into mounted position using the transmission jack matching the crossmember to the marked locations on the body made during removal. 3. Install the four mounting bolts (6) securing the front crossmember (1) to the body. Tighten the crossmember mounting bolts to 190 Nm (140 ft. lbs.). 4. Remove the transmission jack. 5. Remove the bungee cord or other supporting the steering gear (2). 6. Install the two bolts (1) securing the steering gear (2) to the crossmember. Tighten the steering gear mounting bolts to 70 Nm (52 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar - Removal > Page 5442 7. Install the two cushions (bushings) on the stabilizer bar utilizing the slit cut into the cushion sides. 8. Install the two stabilizer bushing retainers (3) over the cushions. 9. Install the screws (1) securing the stabilizer bushing retainers (3) to the crossmember. Tighten all four stabilizer bar cushion retainer screws to 30 Nm (22 ft. lbs.). 10. Attach the stabilizer bar link (1) at each end of the stabilizer bar (2). At each link, install and tighten the nut (3) while holding the stabilizer bar link lower stud stationary. Tighten the nuts to 58 Nm (43 ft. lbs.). 11. Position the power steering hose routing clamps (2) on the crossmember. Install the fasteners. Tighten the screw to 8 Nm (71 in. lbs.). 12. Install the rear engine mount. See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Engine Mount Insulator - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar - Removal > Page 5443 13. If equipped, install the engine belly pan. See: Body and Frame/Exterior Moulding / Trim/Underbody Cover/Service and Repair/Belly Pan Installation 14. Lower the vehicle. 15. Perform wheel alignment as necessary paying special attention to front camber and caster. The crossmember may need to be shifted on its mounts slightly to gain preferred setting. See: Alignment/Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar - Removal > Page 5444 Stabilizer Bar: Service and Repair Rear Suspension Stabilizer Bar - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Vehicle Damage Warnings . 1. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 2. On both sides of the vehicle, while holding the stabilizer bar link upper stud stationary, remove the nut (1) securing the link to the stabilizer bar (3). 3. On both sides of the vehicle, remove the screws (3) securing the stabilizer bushing retainers (1) to the crossmember. 4. Remove the two stabilizer bushing retainers. 5. Remove the stabilizer bar (2) from the vehicle. 6. If required, remove the two cushions from the stabilizer bar utilizing the slit cut into the cushions (bushings). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar - Removal > Page 5445 Stabilizer Bar: Service and Repair Rear Suspension Stabilizer Bar - Installation INSTALLATION 1. If required, install the two cushions on the stabilizer bar (one on each side) utilizing the slit cut into the cushions (bushings). 2. Position the stabilizer bar (2) on the rear crossmember. 3. Install the two retainers (1) over the cushions at the mounting holes and install the retainer screws (3). Do not tighten the screws at this time. 4. On each side of the vehicle, install the stabilizer link upper stud in the end of the stabilizer bar (3). Install the nut (1) on each upper stud and while holding the stabilizer link stud stationary, tighten the nut (2) to 50 Nm (37 ft. lbs.). 5. Tighten the cushion retainer screws to 34 Nm (25 ft. lbs.). 6. Lower the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking Suspension Strut / Shock Absorber: Customer Interest Suspension - Rough Handling/Front Strut(s) Leaking NUMBER: 02-001-09 GROUP: Springs/Shocks DATE: August 08, 2009 SUBJECT: Poor Handling and/or Strut Leaking and/or Rides Rough OVERVIEW: This bulletin involves replacing the, jounce bumper and dust shield with a new design if front struts are replaced due to degraded performance. MODELS: 2007-2009 (PM) Caliber 2007-2009 (MK) Compass/Patriot NOTE: This Bulletin applies to vehicles built before April 23, 2009 (MDH 0423XX). SYMPTOM/CONDITION: The front strut(s) leaking and/or the vehicle handles rough. DISCUSSION: When replacing front struts due to degraded performance. The jounce bumper/dust shield must be replaced with the latest design. Perform the inspection/repair procedure to determine if jounce bumper/dust shield requires replacement SPECIAL TOOLS/EQUIPMENT REQUIRED: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 5454 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is the jounce bumper and dust shield a one-piece black rubber part? a. Yes >> Proceed to b. No >> This bulletin does not apply the latest part design has been implemented. 2. Remove both right and left front struts. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Removal. NOTE: Even though one front strut needs replacement both jounce bumper/dust shields require replacement. 3. Disassemble the undamaged strut assembly. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly> Disassembly. 4. Remove the undamaged front strut assembly jounce bumper. 5. Install jounce bumper(s) p/n 05171137AB on the replacement and undamaged front strut assembly. 6. Install dust shield cover(s) p/n 05171132AC on both the strut assemblies. 7. Assemble the strut assemblies. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Assembly. 8. Install the strut assemblies. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 5455 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Rough Handling/Front Strut(s) Leaking NUMBER: 02-001-09 GROUP: Springs/Shocks DATE: August 08, 2009 SUBJECT: Poor Handling and/or Strut Leaking and/or Rides Rough OVERVIEW: This bulletin involves replacing the, jounce bumper and dust shield with a new design if front struts are replaced due to degraded performance. MODELS: 2007-2009 (PM) Caliber 2007-2009 (MK) Compass/Patriot NOTE: This Bulletin applies to vehicles built before April 23, 2009 (MDH 0423XX). SYMPTOM/CONDITION: The front strut(s) leaking and/or the vehicle handles rough. DISCUSSION: When replacing front struts due to degraded performance. The jounce bumper/dust shield must be replaced with the latest design. Perform the inspection/repair procedure to determine if jounce bumper/dust shield requires replacement SPECIAL TOOLS/EQUIPMENT REQUIRED: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 5461 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is the jounce bumper and dust shield a one-piece black rubber part? a. Yes >> Proceed to b. No >> This bulletin does not apply the latest part design has been implemented. 2. Remove both right and left front struts. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Removal. NOTE: Even though one front strut needs replacement both jounce bumper/dust shields require replacement. 3. Disassemble the undamaged strut assembly. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly> Disassembly. 4. Remove the undamaged front strut assembly jounce bumper. 5. Install jounce bumper(s) p/n 05171137AB on the replacement and undamaged front strut assembly. 6. Install dust shield cover(s) p/n 05171132AC on both the strut assemblies. 7. Assemble the strut assemblies. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Assembly. 8. Install the strut assemblies. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 5462 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension Strut Assembly - Description Suspension Strut / Shock Absorber: Description and Operation Front Suspension Strut Assembly Description DESCRIPTION A Macpherson type design strut assembly is used in place of the front suspension upper control arm and upper ball joint. The bottom of the strut mounts directly to the steering knuckle using two attaching bolts and nuts going through the strut clevis bracket and knuckle. The top of the strut mounts directly to the strut tower of the vehicle using the three threaded studs on the strut assembly's upper mount. The strut assembly includes the following components: - Upper mount (rubber isolated) (2) - Bearing (3) - Upper spring seat and isolator (4) - Coil spring (5) - Dust shield and jounce bumper (6) - Lower spring isolator (7) - Strut (damper) (8) Each component is serviced by removing the strut assembly from the vehicle and disassembling it. Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. If a coil spring requires replacement, be sure that it is replaced with a spring meeting the correct load rating for the vehicle and its specific options. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension Strut Assembly - Description > Page 5465 Suspension Strut / Shock Absorber: Description and Operation Front Suspension Strut Assembly Operation OPERATION The strut assembly cushions the ride of the vehicle, controlling vibration, jounce and rebound of the suspension. The coil spring controls ride quality and maintains proper ride height. The spring isolators isolate the coil spring at the top and bottom from coming into metal-to-metal contact with the upper mounting seat and the strut. The jounce bumper limits suspension travel and metal-to-metal contact under full jounce condition. The strut dampens jounce and rebound motions of the coil spring and suspension. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension Strut Assembly - Description > Page 5466 Suspension Strut / Shock Absorber: Description and Operation Rear Shock Absorber - Description DESCRIPTION A coil-over shock absorber assembly supports each side of the vehicle. The bottom of the shock assembly mounts to the lower control arm. The top of the shock assembly mounts to the body. The shock assembly includes the following major components: - Upper bushing (3) - Upper mounting bracket (4) - Upper spring isolator (5) - Sleeve (6) - Lower bushing (7) - Jounce bumper (9) - Dust shield (10) - Coil spring (11) - Lower spring isolator (12) - Shock absorber (13) Later build vehicles also have a noise abatement cap located on top of the assembly. Each component is serviced by removing the shock assembly from the vehicle and disassembling it. Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. If a coil spring requires replacement, be sure that it is replaced with a spring meeting the correct load rating for the vehicle and its specific options. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension Strut Assembly Suspension Strut / Shock Absorber: Testing and Inspection Front Suspension Strut Assembly STRUT ASSEMBLY Inspect the strut assembly for the following conditions: - Inspect for a damaged or broken coil spring (5). - Inspect for a torn or damaged dust shield (6). - Lift the dust shield and inspect the strut assembly for evidence of fluid running from the upper end of the strut fluid reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit). A slight amount of seepage between the strut shaft and strut shaft seal is not unusual and does not affect performance of the strut assembly. - Inspect the jounce bumper for signs of damage or deterioration. - Inspect the clearance between the shock tower and the coil spring. Make sure no fasteners are protruding through the shock tower possibly contacting the coil spring and strut. Because of the minimum clearance in this area, installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. CAUTION: At no time when servicing a vehicle can a sheet metal screw, bolt or other metal fastener be installed into the strut tower (1) to take the place of an original plastic clip. Also, do not drill holes into the front strut tower for the installation of any metal fasteners into the shock tower area indicated (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension Strut Assembly > Page 5469 Suspension Strut / Shock Absorber: Testing and Inspection Rear Shock Absorber, Coil-Over SHOCK ABSORBER Inspect the shock absorber for damage and evidence of fluid running from the upper end of the fluid reservoir. (Actual leakage will be a stream of fluid running down the side of the reservoir tube and dripping off lower end of unit). A slight amount of seepage between the shaft and shaft seal is not unusual and does not affect performance of the shock absorber. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement Suspension Strut / Shock Absorber: Removal and Replacement Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Technician Safety Information . 1. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). NOTE: If both strut assemblies are to be removed, mark the strut assemblies right or left and keep the parts separated to avoid mix-up. Not all parts of the strut assembly are interchangeable side-to-side. 3. Remove the screw (1) securing the flex hose (2) routing bracket to the strut (6). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5472 4. While holding the stabilizer bar link (1) stud stationary, remove the nut (4) securing the link to the strut (3). CAUTION: The strut assembly-to-knuckle attaching bolts (5) are serrated and must not be turned during removal. Hold the bolts stationary in the knuckle while removing the nuts, then tap the bolts out using a pin punch. 5. While holding the bolt heads stationary, remove the two nuts (2) from the bolts (5) attaching the strut (3) to the knuckle (6). 6. Remove the two bolts (5) attaching the strut (3) to the knuckle (6) using a pin punch. 7. Lower the vehicle just enough to open the hood without allowing the tires to touch the floor. 8. Remove the three nuts (1) attaching the strut assembly (2) upper mount to the strut tower. 9. Remove the strut assembly (2) from the vehicle. 10. For disassembly, See: Overhaul/Front Suspension Strut Assembly - Disassembly. Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5473 1. Raise the strut assembly (2) into the strut tower, aligning the three studs on the strut assembly upper mount with the holes in strut tower. Install the three mounting nuts (1) on the studs. Tighten the three nuts to 48 Nm (35 ft. lbs.). CAUTION: The strut assembly-to-knuckle attaching bolts (5) are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the knuckle. 2. Position the lower end of the strut assembly (3) in line with the upper end of the knuckle (6), aligning the mounting holes. Install the two attaching bolts (5). Install the nuts (2). While holding the bolts in place, tighten the nuts to 110 Nm (81 ft. lbs.). 3. Attach the stabilizer bar link (1) to the strut (3). Install and tighten the nut (4) while holding the stabilizer bar link stud stationary. Tighten the nut to 58 Nm (43 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5474 4. Secure the flex hose (2) routing bracket to the strut (6) with the mounting screw (1). Tighten the mounting screw to 13 Nm (120 in. lbs.). 5. Install tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Perform wheel alignment as necessary. See: Alignment/Service and Repair Rear Shock Absorber, Coil-Over - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Vehicle Damage Warnings . 1. Remove the interior rear quarter trim panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal 2. Remove the two nuts (1) securing the shock assembly (2) to the body bracket (3). 3. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5475 4. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. 5. Remove the shock lower mounting nut (3) and bolt (1). 6. Lower the shock assembly (2) out of the body bracket (1) and lift out over rear suspension. Rear Shock Absorber, Coil-Over - Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5476 1. Insert the lower end of the shock assembly (2) down though the lower control arm from above just enough to clear the body, then lift it up into the body bracket (1). 2. Install the mounting bolt (1) and nut (3) fastening the shock assembly (2) to the lower control arm (4). Do not tighten at this time. 3. Install the tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 4. Lower the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5477 5. install the two nuts (1) securing the shock assembly (2) to the body bracket (3). Tighten the mounting nuts to 48 Nm (35 ft. lbs.). 6. Install the interior rear quarter trim panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation 7. Position the vehicle on an alignment rack/drive-on lift. Raise the lift as necessary to access the shock mounting bolt (1) and nut (3). 8. Tighten the shock assembly lower mounting bolt nut (3) to 99 Nm (73 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5478 Suspension Strut / Shock Absorber: Overhaul Front Suspension Strut Assembly - Disassembly DISASSEMBLY NOTE: The strut assembly must be removed from the vehicle for it to be disassembled and assembled. See: Removal and Replacement/Front Strut / Shock/Removal For the disassembly and assembly of the strut assembly, use strut spring compressor, team PSE tool 223-7400, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions closely. WARNING: Do not remove the strut rod nut before the coil spring is properly compressed. The coil spring is held under pressure. The coil spring must be compressed, removing spring tension from the upper mount and bearing, before the strut rod nut is removed. 1. If both struts are being serviced at the same time, mark both the coil spring and strut assembly according to which side of the vehicle the strut is being removed from. 2. Position the strut assembly (2) in the strut coil spring compressor (1) following the manufacturer's instructions and set the lower and upper hooks of the compressor on the coil spring. Position the strut clevis bracket (2) straight outward, away from the compressor. 3. Compress the coil spring until all coil spring tension is removed from the upper mount and bearing. CAUTION: Never use impact or high speed tools to remove the strut rod nut. Damage to the strut internal bearings can occur. 4. Once the spring is sufficiently compressed, install Strut Nut Wrench 9362 (2) on the strut rod nut. Next, install Strut Shaft Socket 9894 (1) on the end of the strut rod. While holding the strut rod from turning, remove the nut using the strut nut wrench. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5479 5. Remove the clamp (if installed) from the bottom of the coil spring and remove the strut (damper) (8) out through the bottom of the coil spring. The dust shield and jounce bumper will come out with the strut. 6. Remove the lower spring isolator (7) from the strut seat. 7. Slide the dust shield and jounce bumper (6) from the strut rod. 8. Remove the upper mount (2) and bearing (3) from the top of the upper spring seat and isolator (4). 9. Remove the upper spring seat and isolator (4) from the top of the coil spring (5). NOTE: If the coil spring needs to be serviced, proceed with the next step, otherwise, proceed with 11. 10. Release the tension from the coil spring by backing off the compressor drive completely. Push back the compressor hooks and remove the coil spring. 11. Inspect the strut assembly components for the following and replace as necessary: - Inspect the strut (damper) (8) for shaft binding over the full stroke of the shaft. - Inspect the jounce bumper (with dust shield) (6) for cracks and signs of deterioration. - Check the upper mount (2) for cracks and distortion and its retaining studs for any sign of damage. - Check the bearing (3) for any binding. - Check the upper spring seat and isolator (4) for cracks and distortion. - Inspect the upper and lower spring isolators (4, 7) for material deterioration and distortion. - Inspect the coil spring (5) for any sign of damage to the coating. NOTE: For reassembly, See: Front Suspension Strut Assembly - Assembly . Front Suspension Strut Assembly - Assembly ASSEMBLY NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step, otherwise, proceed with 3. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5480 CAUTION: When installing the coil spring, make sure the end with the ID tag is placed downward, otherwise spring-to-body contact will occur after strut assembly installation. 1. Place the coil spring in the spring compressor following the manufacturer's instructions. Before compressing the spring, rotate the spring so the end of the bottom coil is at approximately the 9 o'clock position as viewed above (or to where the spring was when removed from the compressor). This action will allow the strut (damper) clevis bracket to be positioned outward, away from the compressor once installed. 2. Slowly compress the coil spring until enough room is available for strut assembly reassembly. 3. Install the upper spring seat and isolator (4) on top of the coil spring (5). 4. Install the bearing (3) and upper mount (2) on top of the upper spring seat and isolator (4). 5. Install the lower spring isolator (7) on the spring seat on the strut (8). 6. Slide the dust shield and jounce bumper (6) onto the strut rod. 7. Install the strut up through the bottom of the coil spring and upper spring seat, mount, and bearing until the lower spring seat contacts the lower end of the coil spring. Rotate the strut as necessary until the end of the bottom coil (2) comes in contact with the stop (1) built into the lower spring isolator. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5481 8. While holding the strut in position, install the nut (1) on the end of the strut rod. CAUTION: Never use impact or high speed tools to remove the strut rod nut. Damage to the strut internal bearings can occur. 9. Install Strut Nut Wrench 9362 (2) on the strut rod nut. Next, install Strut Shaft Socket 9894 (1) on the end of the strut rod. While holding the strut rod from turning, tighten the strut rod nut to 60 Nm (44 ft. lbs.) using a torque wrench on the end of the Strut Nut Wrench 9362 (2). 10. Slowly release the tension from the coil spring by backing off the compressor (1) drive completely. As the tension is relieved, make sure the upper mount and bearing align properly. Verify the upper mount does not bind when rotated. 11. Remove the strut assembly from the spring compressor. 12. Install the strut assembly on the vehicle. See: Removal and Replacement/Front Strut / Shock/Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5482 Disassembly DISASSEMBLY NOTE: The shock assembly must be removed from the vehicle for it to be disassembled and assembled. See: Removal and Replacement/Rear Shock Absorber/Rear Shock Absorber, Coil-Over - Removal For the disassembly and assembly of the shock assembly, use Strut Spring Compressor, team PSE tool 223-7400, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions closely. WARNING: Do not remove the shock rod nut before the coil spring is properly compressed. The coil spring is held under pressure. The coil spring must be compressed, removing spring tension from the upper mounting bracket, before the shock rod nut is removed. 1. If both shocks are being serviced at the same time, mark both the coil spring and shock assembly according to which side of the vehicle the shock is being removed from. 2. If equipped, remove the noise abatement cap from top of the shock assembly. 3. Position the shock assembly (2) in the strut spring compressor (1) following the manufacturer's instructions and set the lower and upper hooks of the compressor on the coil spring. 4. Compress the coil spring until all spring tension is removed from the upper mounting bracket and bushings. CAUTION: Never use impact or high speed tools to remove the shock rod nut. Damage to the shock internal bearings can occur. 5. Once the spring is sufficiently compressed, install Snap-On(R) Shock Absorber Socket A139, or equivalent, on the end of the shock rod (1). While holding the shock rod from turning, remove the nut (2) using a wrench. Remove the washer below the nut. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5483 6. Remove the shock absorber (13) out through the bottom of the coil spring (11). The washer (8), jounce bumper (9), dust shield (10) and lower spring isolator (12) will come out with the shock. 7. Slide the washer (8), jounce bumper (9), dust shield (10) from the shock rod. 8. Remove the lower spring isolator (12) from the shock spring seat. 9. Remove the upper mounting bracket (4), bushings (3, 7), sleeve (6) and upper spring isolator (5) from the top of the spring. 10. Remove the bushings (3, 7), sleeve (6) and upper spring isolator (5) from the upper mounting bracket (4). NOTE: If the coil spring needs to be serviced, proceed with the next step, otherwise, proceed with 12. 11. Release the tension from the coil spring by backing off the compressor drive completely. Push back the compressor hooks and remove the coil spring. 12. Inspect the shock assembly components for the following and replace as necessary: - Inspect the shock (13) for shaft binding over the full stroke of the shaft. - Inspect the jounce bumper (9) for cracks and signs of deterioration. - Inspect the dust shield (10) for cracks and tears. - Check the upper mounting bracket (4) for cracks and distortion and its retaining studs for any sign of damage. - Inspect the upper (3) and lower (7) bushings, for material deterioration and signs of deterioration. Inspect the sleeve (6) for wear and distortion. - Inspect the upper (5) and lower (12) spring isolators for material deterioration and distortion. - Inspect the coil spring (11) for any sign of damage to the coating. NOTE: For reassembly, See: Rear Suspension Assembly ASSEMBLY NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step, otherwise, proceed with 3. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5484 CAUTION: When installing the coil spring, make sure the end with the ID tag is placed upward, otherwise spring-to-body contact will occur after shock assembly installation. 1. Place the coil spring in the spring compressor following the manufacturer's instructions. 2. Slowly compress the coil spring until enough room is available for shock assembly reassembly. 3. Assemble the bushings (3, 7) and sleeve (6) through the upper mounting bracket (4). 4. Install the upper spring isolator (5) on the upper mounting bracket (4). 5. Install the upper mounting bracket (4) on top of the coil spring. 6. Install the lower spring isolator (12) on the spring seat of the shock absorber (13). 7. Slide the dust shield (10), jounce bumper (9) and washer (8) onto the shock rod. 8. Install the shock absorber (13) up through the bottom of the coil spring and upper mounting bracket until the lower spring seat contacts the lower end of the coil spring. 9. While holding the shock absorber in position, install the washer (2) and nut (1) on the end of the shock rod. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5485 CAUTION: Never use impact or high speed tools to remove the shock rod nut. Damage to the shock internal bearings can occur. 10. Install Snap-On(R) Shock Absorber Socket A139, or equivalent, on the end of the shock rod (1). While holding the shock rod from turning, tighten the nut (2) using a crows foot wrench and a torque wrench. Tighten the shock rod nut to 24 Nm (18 ft. lbs.). 11. Turn the upper mounting bracket or shock absorber as necessary until the mounting studs on the mounting bracket line up with the lower mounting bolt eyelet at the bottom of the shock absorber. 12. Slowly release the tension from the coil spring by backing off the compressor (1) drive completely. 13. Remove the shock assembly from the spring compressor. 14. If equipped, install the noise abatement cap on top of the shock assembly. 15. Install the shock assembly on the vehicle. See: Removal and Replacement/Rear Shock Absorber/Rear Shock Absorber, Coil-Over Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > Customer Interest for Suspension Travel Bumper: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking Suspension Travel Bumper: Customer Interest Suspension - Rough Handling/Front Strut(s) Leaking NUMBER: 02-001-09 GROUP: Springs/Shocks DATE: August 08, 2009 SUBJECT: Poor Handling and/or Strut Leaking and/or Rides Rough OVERVIEW: This bulletin involves replacing the, jounce bumper and dust shield with a new design if front struts are replaced due to degraded performance. MODELS: 2007-2009 (PM) Caliber 2007-2009 (MK) Compass/Patriot NOTE: This Bulletin applies to vehicles built before April 23, 2009 (MDH 0423XX). SYMPTOM/CONDITION: The front strut(s) leaking and/or the vehicle handles rough. DISCUSSION: When replacing front struts due to degraded performance. The jounce bumper/dust shield must be replaced with the latest design. Perform the inspection/repair procedure to determine if jounce bumper/dust shield requires replacement SPECIAL TOOLS/EQUIPMENT REQUIRED: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > Customer Interest for Suspension Travel Bumper: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 5494 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is the jounce bumper and dust shield a one-piece black rubber part? a. Yes >> Proceed to b. No >> This bulletin does not apply the latest part design has been implemented. 2. Remove both right and left front struts. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Removal. NOTE: Even though one front strut needs replacement both jounce bumper/dust shields require replacement. 3. Disassemble the undamaged strut assembly. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly> Disassembly. 4. Remove the undamaged front strut assembly jounce bumper. 5. Install jounce bumper(s) p/n 05171137AB on the replacement and undamaged front strut assembly. 6. Install dust shield cover(s) p/n 05171132AC on both the strut assemblies. 7. Assemble the strut assemblies. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Assembly. 8. Install the strut assemblies. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > Customer Interest for Suspension Travel Bumper: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 5495 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Travel Bumper: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking Suspension Travel Bumper: All Technical Service Bulletins Suspension - Rough Handling/Front Strut(s) Leaking NUMBER: 02-001-09 GROUP: Springs/Shocks DATE: August 08, 2009 SUBJECT: Poor Handling and/or Strut Leaking and/or Rides Rough OVERVIEW: This bulletin involves replacing the, jounce bumper and dust shield with a new design if front struts are replaced due to degraded performance. MODELS: 2007-2009 (PM) Caliber 2007-2009 (MK) Compass/Patriot NOTE: This Bulletin applies to vehicles built before April 23, 2009 (MDH 0423XX). SYMPTOM/CONDITION: The front strut(s) leaking and/or the vehicle handles rough. DISCUSSION: When replacing front struts due to degraded performance. The jounce bumper/dust shield must be replaced with the latest design. Perform the inspection/repair procedure to determine if jounce bumper/dust shield requires replacement SPECIAL TOOLS/EQUIPMENT REQUIRED: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Travel Bumper: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 5501 PARTS REQUIRED: REPAIR PROCEDURE: 1. Is the jounce bumper and dust shield a one-piece black rubber part? a. Yes >> Proceed to b. No >> This bulletin does not apply the latest part design has been implemented. 2. Remove both right and left front struts. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Removal. NOTE: Even though one front strut needs replacement both jounce bumper/dust shields require replacement. 3. Disassemble the undamaged strut assembly. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly> Disassembly. 4. Remove the undamaged front strut assembly jounce bumper. 5. Install jounce bumper(s) p/n 05171137AB on the replacement and undamaged front strut assembly. 6. Install dust shield cover(s) p/n 05171132AC on both the strut assemblies. 7. Assemble the strut assemblies. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Assembly. 8. Install the strut assemblies. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 2-Front Suspension > STRUT, Suspension, Assembly > Installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Travel Bumper: > 02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 5502 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Rear Suspension Trailing Link - Removal Trailing Arm: Service and Repair Rear Suspension Trailing Link - Removal REMOVAL 1. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 3. Remove the screw (2) securing the brake flex hose (1) to the trailing link (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Rear Suspension Trailing Link - Removal > Page 5507 4. Remove the nut (1) securing the brake tube routing bracket to the trailing link. 5. Remove the brake tube (3) from the routing clip (2) on the trailing link. 6. Remove the two bolts (1) securing disc brake caliper adapter (3) to the brake support plate (4). 7. Remove the disc brake caliper (2) and adapter (3) as an assembly. Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose and tubing when doing this. 8. If equipped, remove the screw (4) fastening the wheel speed sensor (3) to the trailing link (2). 9. If equipped, remove the routing clip (1) fastening the wheel speed sensor (3) to the trailing link (2). 10. Remove the brake rotor, then hub and bearing. See: Wheel Bearing/Service and Repair/Rear Hub and Bearing - Removal 11. Remove the parking brake cable from the lever on the parking brake shoe. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Rear Suspension Trailing Link - Removal > Page 5508 12. Remove the hair pin (1) securing the parking brake cable (2) to the brake support plate (3). 13. Slide the brake support plate (3) with parking brake shoes off the end of the parking brake cable (2) and remove. 14. Pull the parking brake cable from the trailing link. 15. Remove the bolt (2) securing the toe link (3) to the trailing link. 16. Remove the nut (2) and bolt securing the lower control arm to the trailing link (3). 17. Remove the nut (1) and bolt securing the upper control arm to the trailing link (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Rear Suspension Trailing Link - Removal > Page 5509 18. Remove the two bolts (2) fastening the leading end of the trailing link (3) to the body (1). 19. Remove the trailing link. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Rear Suspension Trailing Link - Removal > Page 5510 Trailing Arm: Service and Repair Rear Suspension Trailing Link - Installation INSTALLATION 1. Position the trailing link and install the two bolts (2) fastening the leading end of the trailing link (3) to the body (1). Tighten the two mounting bolts to 110 Nm (81 ft. lbs.). 2. Position the upper control arm on the trailing link (3) and install the bolt and nut (1) securing the arm to the link. Tighten the mounting bolt nut to 95 Nm (70 ft. lbs.). 3. Position the lower control arm on the trailing link (3) and install the bolt and nut (2) securing the arm to the link. Tighten the mounting bolt nut to 95 Nm (70 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Rear Suspension Trailing Link - Removal > Page 5511 4. Install the bolt (2) securing the toe link to the trailing link. To install the bolt it may be necessary to flex the trailing link body mount bushing inward or outward using an appropriate prying tool. Tighten the mounting bolt to 95 Nm (70 ft. lbs.). 5. Insert the parking brake cable through the trailing link from the inboard side. 6. Slide the parking brake cable (2) into the brake support plate (3) with parking brake shoes. 7. Install the hair pin (1) securing the parking brake cable (2) to the brake support plate (3). 8. Install the parking brake cable onto the lever on the parking brake shoe. 9. If equipped, position the wheel speed sensor (3) and install the screw (4) fastening the sensor to the trailing link (2). Tighten the mounting screw to 18 Nm (13 ft. lbs.). 10. If equipped, position the wheel speed sensor (3) and install the routing clip (1) fastening the sensor to the trailing link (2). 11. Install the hub and bearing, then install the brake rotor onto the wheel studs. See: Wheel Bearing/Service and Repair/Rear Hub and Bearing Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Rear Suspension Trailing Link - Removal > Page 5512 12. Slide the disc brake caliper (2) and adapter (3) assembly over brake rotor and brake support plate. 13. Install the two bolts (1) securing disc brake caliper adapter (3) to the brake support plate (4). Tighten the mounting bolts to 71 Nm (52 ft. lbs.). 14. Position the brake tube on the trailing link inserting the tube into the routing clip (2) and routing bracket over the welded stud. 15. Install the nut (1) on the welded stud. Tighten the nut to 15 Nm (11 ft. lbs.). 16. Position the brake flex hose (1) at the trailing link (3) bracket and install the mounting screw (2). Tighten the screw to 23 Nm (17 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Rear Suspension Trailing Link - Removal > Page 5513 17. Install tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 18. Lower the vehicle. 19. Perform wheel alignment as necessary. See: Alignment/Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Description and Operation > Front Hub and Bearing - Description Wheel Bearing: Description and Operation Front Hub and Bearing - Description DESCRIPTION The wheel bearing (5) and hub (3) are pressed into the knuckle (1). The wheel bearing is secured in place using a snap ring. One side of the wheel bearing has an integrated magnetic encoder ring for wheel speed sensor usage as equipped. It is important that the wheel speed sensor magnetic encoder ring (dark band) (3) be positioned to the inside of the knuckle or the wheel speed sensor will not operate correctly. The wheel bearing is a Unit 1 type cartridge bearing that requires no maintenance. The wheel bearing can be serviced separately from the hub. The hub supports the driveline halfshaft outer constant velocity (C/V) joint. Each is splined and meshes in the center of the hub. The outer C/V joint is retained to the hub using a nut. The nut is locked to the outer C/V stub shaft using a cotter pin. The hub has five studs pressed into its flange. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Description and Operation > Front Hub and Bearing - Description > Page 5518 Wheel Bearing: Description and Operation Rear Hub and Bearing - Description DESCRIPTION The rear wheel bearing and wheel mounting hub used on this vehicle are a one-piece sealed unit or hub and bearing assembly. It is permanently lubricated when assembled and is sealed for life. There is no periodic lubrication or maintenance recommended for these units. The hub and bearing (5) is mounted to the trailing link (1). All vehicles have a magnetic encoder integrated into the right rear hub and bearing for speed sense. Vehicles equipped with antilock brakes have a magnetic encoder integrated into both rear hub and bearings. The encoder works with the rear wheel speed sensors to provide wheel speed signal. The sensor mounts by screw to the rear of the hub and bearing. The only serviceable components of the hub and bearing are the wheel mounting studs pressed into the hub. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front Hub and Bearing Wheel Bearing: Testing and Inspection Front Hub and Bearing WHEEL BEARING AND HUB NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weeping from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Testing and Inspection Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front Hub and Bearing > Page 5521 Wheel Bearing: Testing and Inspection Rear Hub and Bearing HUB AND BEARING NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub and bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Testing and Inspection Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal Wheel Bearing: Service and Repair Front Hub and Bearing - Removal REMOVAL NOTE: The removal and installation of the wheel bearing and hub from the knuckle is only to be done with the knuckle removed from the vehicle. 1. Remove the steering knuckle from the vehicle. See: Front Steering Knuckle/Service and Repair/Front Steering Knuckle - Removal 2. Position the knuckle support fixture 9712 as follows: a. For left side knuckles, place the locator block (2) to the left side (4) on the Fixture. The side of the locator block with the angle cut goes downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54 Nm (40 ft. lbs.). b. For right side knuckles, place the locator block (2) to the right side (3) on the Fixture. The side of the locator block with the angle cut goes downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54 Nm (40 ft. lbs.). 3. Install the knuckle in the Fixture as shown, guiding the steering arm (1) to rest on the locator block (3) and the brake caliper mounting bosses on the two Fixture pins (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5524 4. Place the Fixture (3) with knuckle in an arbor press. 5. Position Remover/Installer 9712-2 (2), in the small end of the hub. Lower the arbor press ram (1) and remove the hub from the wheel bearing and knuckle. The bearing race will normally come out of the wheel bearing with the hub as it is pressed out of the bearing. 6. Remove the knuckle from the Fixture and turn it over. 7. Remove the snap ring (2) from the knuckle using an appropriate pair of snap ring pliers (1). 8. Place the knuckle back in the Fixture (3) in the arbor press ram. 9. Place Installer (2) MD-998334, on the outer race of the wheel bearing. Lower the arbor press ram (1) and remove the wheel bearing from the knuckle. 10. Remove the knuckle and tools from arbor press. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5525 11. If the bearing race is still pressed onto the hub, install the Bearing Splitter (5), Special Tool 1130, between the hub flange and the bearing inner race (4). 12. Place the hub, bearing race and Bearing Splitter in an arbor press. The press support blocks must not obstruct the wheel hub while it is being pressed out of the bearing race. 13. Place Remover/Installer 9712-2 (2) in the end of the hub (3). Lower the arbor press ram (1) and remove the hub from the bearing race. NOTE: For installation, See: Front Hub and Bearing - Installation . Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5526 Wheel Bearing: Service and Repair Front Hub and Bearing - Installation INSTALLATION CAUTION: When installing the wheel bearing (1) in the knuckle (2) it is important to place the side of bearing with the wheel speed sensor magnetic encoder ring (dark band) (3) in the knuckle first. Otherwise, the wheel speed sensor will not operate correctly. 1. Wipe the bearing bore of the knuckle clean of any grease or dirt with a clean, dry shop towel. 2. Place the knuckle in an arbor press supporting the knuckle from underneath using Cup 6310-1 (4.) 3. Place the NEW wheel bearing (5) magnetic encoder ring side down (see above Caution) into the bore of the knuckle. Be sure the wheel bearing is placed squarely into the bore. 4. Place Receiver 8498 (3), larger inside diameter end down over the outer race of the wheel bearing. 5. Place Disc 6310-2 (2) into top of Receiver 8498. Lower the arbor press ram (1) and press the wheel bearing into the knuckle until it is bottomed in the bore of the knuckle. 6. Remove the knuckle and tools from the arbor press. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5527 7. Install a NEW snap ring (2) in the knuckle using an appropriate pair of snap ring pliers (1). Make sure the snap ring is fully seated. 8. Place the knuckle in an arbor press. Support the knuckle from underneath using Remover/Installer MB-990799 (3), smaller end up against the wheel bearing inner race. 9. Place the hub (4) in the wheel bearing making sure it is square with the bearing inner race. 10. Position Remover/Installer 9712-2 (2) in the end of the hub. Lower the arbor press ram (1) and press the hub into the wheel bearing until it bottoms. 11. Remove the knuckle and tools from the press. 12. Verify the hub turns smoothly without rubbing or binding. 13. Install the knuckle on the vehicle. See: Front Steering Knuckle/Service and Repair/Front Steering Knuckle - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5528 Wheel Bearing: Service and Repair Rear Hub and Bearing - Removal REMOVAL NOTE: Before proceeding, See: Service Precautions/Vehicle Damage Warnings . 1. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. 3. Remove the disc brake caliper (2) lower guide pin bolt (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5529 CAUTION: When moving rear brake caliper upward, use extreme care not to damage or overextend the flex hose. Damage may occur. 4. Rotate the caliper upward hinging off the upper guide pin bolt. Rotate the caliper upward just enough to allow brake rotor removal. Hang the caliper assembly in this position using wire or a bungee cord. 5. Remove any clips (2) retaining the brake rotor (3) to the wheel mounting studs. 6. Slide the brake rotor (3) off the hub and bearing (1). 7. Remove the screw (1) fastening the wheel speed sensor head (3) in the rear of the hub and bearing (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5530 8. Remove the four bolts (1) securing the hub and bearing (2) to the trailing link. 9. Remove the hub and bearing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5531 Wheel Bearing: Service and Repair Rear Hub and Bearing - Installation FRONT-WHEEL-DRIVE NOTE: If equipped, make sure the wheel speed sensor mount on the rear of the hub and bearing is directed toward the front of the vehicle. 1. Position the hub and bearing on the brake support plate and trailing link. 2. Install the four bolts (1) securing the hub and bearing (2) to the trailing link. Tighten the bolts to 105 Nm (77 ft. lbs.). NOTE: Before installing the wheel speed sensor head (3) into the rear of the hub and bearing (2), inspect the O-ring seal to make sure it is not dislodged, split, cut or damaged in any way. Replace the O-ring as necessary. 3. If equipped with a wheel speed sensor, install the wheel speed sensor head (3) into the rear of the hub and bearing (2). 4. If equipped with a wheel speed sensor, install the wheel speed sensor head mounting screw (1). Tighten the screw to 10 Nm (89 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5532 5. Slide the brake rotor (3) over the parking brake shoes and onto the hub and bearing (1). 6. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 7. Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 60 Nm (44 ft. lbs.). 8. Install tire and wheel assembly (1) See: Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. 10. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving it. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications > Front Suspension Axle Nut: Specifications Front Suspension AXLE NUT Hub Nut................................................................................................................................................ ....................................................244 Nm (180 ft.lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications > Front Suspension > Page 5538 Axle Nut: Specifications Rear Suspension AXLE NUT Hub Nut................................................................................................................................................ ....................................................245 Nm (181 ft.lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair cr09 HOISTING Refer to Owner's Manual provided with vehicle for proper emergency jacking procedures. WARNING: The hoisting and jack lifting points provided are for a complete vehicle. When the engine or rear suspension is removed from a vehicle, the center of gravity is altered making some hoisting conditions unstable. Properly support or secure vehicle to hoisting device when these conditions exist. CAUTION: Do not position hoisting device on suspension components, damage to vehicle can result.Do not attempt to raise one entire side of the vehicle by placing a floor jack midway between the front and rear wheels. This practice may result in permanent damage to the body. When properly positioned, a floor jack can be used to lift the vehicle and support the raised vehicle with jack stands. A floor jack or any lifting device, must never be used on any part of the underbody other then the described areas. SRT 4 CAUTION: When lifting a Caliber SRT 4 vehicle on a hoist it may be necessary to use 55 mm lift arm spacers to clear the SRT 4 ground effect components. Failure to lift the SRT 4 correctly may result in ground effect component damage. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 5548 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 5549 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Tire Pressure Monitor Receiver / Transponder: Diagrams Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT FRONT (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way > Page 5552 Tire Pressure Monitor Receiver / Transponder: Diagrams Left Rear Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT REAR (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way > Page 5553 Tire Pressure Monitor Receiver / Transponder: Diagrams Right Rear Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-RIGHT REAR (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Description DESCRIPTION A transponder, sometimes referred to as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of a vehicle equipped with Premium TPM. These transponders are used to provide the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. On this vehicle, there is a transponder located in the left front, left rear, and right rear wheelhouse. There is not a transponder located in the right front wheelhouse. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description > Page 5556 Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Operation OPERATION On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (The auto-locating process will start again only if the vehicle has been shut off for approximately 20 minutes or longer). Once the WCM has performed this to the three locations that have transponders, it uses the process-of-elimination theory to figure out the location of the fourth sensor ID. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Removal Front FRONT 1. Remove the wheelhouse splash shield at the transponder requiring service. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 2. Disconnect the wiring harness connector (2) at the transponder (1). 3. Remove the mounting nuts (3), then remove the transponder (1). Rear REAR 1. Remove the wheelhouse splash shield at the transponder requiring service. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 2. Disconnect the wiring harness connector (3) at the transponder (1). 3. Remove the mounting nuts (2), then remove the transponder (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 5559 Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Installation Front FRONT 1. Position the transponder (1) and install the mounting nuts (3). 2. Connect the wiring harness connector (2) to the transponder (1). 3. Install the wheelhouse splash shield and all components removed to access it. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test. Rear REAR 1. Position the transponder (1) and install the mounting nuts (2). 2. Connect the wiring harness connector (3) to the transponder (1). 3. Install the rear wheelhouse splash shield and all components removed to access it. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The Tire Pressure Monitoring (TPM) system has been optimized for the original equipment tires and wheels. TPM system pressures have been established for the tire size equipped on the vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, or style. Aftermarket wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with TPM, as damage to the sensors may result. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: When installing the valve core, be sure to tighten the core to specifications See: Wheels/Specifications . Overtightening by a little as three or four inch pounds can damage the sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a white outline oval (black center) insignia (3) on the sensor body. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor Description > Page 5566 The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by either a solid white oval insignia (3) on the body or. . a solid white oval insignia (3) with 433 printed in the center. The sensors are identical except for the oval insignia. The 433 MHz sensors can either have a black or grey sensor body. CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Sensors may be identified by valve stem cap color. From the factory, 315 MHz sensors have a gray valve stem cap while 433 MHz sensors have a black valve stem cap. Otherwise, once mounted inside a tire and wheel assembly you are not able to visually tell the difference between a 315 MHz and 433 MHz sensor. At that point, the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor Description > Page 5567 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor Description > Page 5568 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer, or from a transponderSee: Relays and Modules - Wheels and Tires/Tire Pressure Monitor Receiver / Transponder/Description and Operation/Tire Pressure Monitoring (TPM) Transponder - Operation. The TPM-RKE Analyzer has the ability to change the sensor's operating mode to PARK MODE and to help diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following operating modes: - SLEEP MODE - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. - PARK MODE - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 psi (6.9 kPa) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 BLOCK MODE - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to PARK MODE using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph (24 km/h). In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 10 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to DRIVE MODE. - DRIVE MODE - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). Anytime the vehicle speed drops below 15 mph (24 km/h), the sensor mode will still be in Drive Mode, but will not transmit until the vehicle reaches speeds over 15 mph (24 km/h) once again. If the vehicle has been stationary for more then 20 minutes, the sensor state will transition to Park Mode. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 mph (24 km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The WCM can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 5571 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 5572 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 5573 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the outer and inner tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. 8. Remove the support and lower the vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 5574 b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 5580 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 5581 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Tire Pressure Monitor Receiver / Transponder: Diagrams Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT FRONT (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way > Page 5584 Tire Pressure Monitor Receiver / Transponder: Diagrams Left Rear Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT REAR (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way > Page 5585 Tire Pressure Monitor Receiver / Transponder: Diagrams Right Rear Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-RIGHT REAR (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Description DESCRIPTION A transponder, sometimes referred to as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of a vehicle equipped with Premium TPM. These transponders are used to provide the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. On this vehicle, there is a transponder located in the left front, left rear, and right rear wheelhouse. There is not a transponder located in the right front wheelhouse. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description > Page 5588 Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Operation OPERATION On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (The auto-locating process will start again only if the vehicle has been shut off for approximately 20 minutes or longer). Once the WCM has performed this to the three locations that have transponders, it uses the process-of-elimination theory to figure out the location of the fourth sensor ID. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Removal Front FRONT 1. Remove the wheelhouse splash shield at the transponder requiring service. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 2. Disconnect the wiring harness connector (2) at the transponder (1). 3. Remove the mounting nuts (3), then remove the transponder (1). Rear REAR 1. Remove the wheelhouse splash shield at the transponder requiring service. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 2. Disconnect the wiring harness connector (3) at the transponder (1). 3. Remove the mounting nuts (2), then remove the transponder (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 5591 Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Installation Front FRONT 1. Position the transponder (1) and install the mounting nuts (3). 2. Connect the wiring harness connector (2) to the transponder (1). 3. Install the wheelhouse splash shield and all components removed to access it. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test. Rear REAR 1. Position the transponder (1) and install the mounting nuts (2). 2. Connect the wiring harness connector (3) to the transponder (1). 3. Install the rear wheelhouse splash shield and all components removed to access it. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The Tire Pressure Monitoring (TPM) system has been optimized for the original equipment tires and wheels. TPM system pressures have been established for the tire size equipped on the vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, or style. Aftermarket wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with TPM, as damage to the sensors may result. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: When installing the valve core, be sure to tighten the core to specifications See: Wheels/Specifications . Overtightening by a little as three or four inch pounds can damage the sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a white outline oval (black center) insignia (3) on the sensor body. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 5597 The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by either a solid white oval insignia (3) on the body or. . a solid white oval insignia (3) with 433 printed in the center. The sensors are identical except for the oval insignia. The 433 MHz sensors can either have a black or grey sensor body. CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Sensors may be identified by valve stem cap color. From the factory, 315 MHz sensors have a gray valve stem cap while 433 MHz sensors have a black valve stem cap. Otherwise, once mounted inside a tire and wheel assembly you are not able to visually tell the difference between a 315 MHz and 433 MHz sensor. At that point, the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 5598 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 5599 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer, or from a transponderSee: Tire Pressure Monitor Receiver / Transponder/Description and Operation/Tire Pressure Monitoring (TPM) Transponder - Operation. The TPM-RKE Analyzer has the ability to change the sensor's operating mode to PARK MODE and to help diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following operating modes: - SLEEP MODE - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. - PARK MODE - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 psi (6.9 kPa) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 BLOCK MODE - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to PARK MODE using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph (24 km/h). In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 10 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to DRIVE MODE. - DRIVE MODE - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). Anytime the vehicle speed drops below 15 mph (24 km/h), the sensor mode will still be in Drive Mode, but will not transmit until the vehicle reaches speeds over 15 mph (24 km/h) once again. If the vehicle has been stationary for more then 20 minutes, the sensor state will transition to Park Mode. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 mph (24 km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The WCM can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 5602 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 5603 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 5604 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the outer and inner tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. 8. Remove the support and lower the vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 5605 b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tires Tires: Description and Operation Tires TIRE Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain, in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: - Rapid acceleration - Severe application of brakes - High-speed driving - Taking turns at excessive speeds - Striking curbs and other obstacles - Operating vehicle with over or under inflated tire pressures Radial ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval shown on Tire Rotation. This will help to achieve a greater tread-life potential. TIRE IDENTIFICATION Tire type, size, load index and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the Tire Identification chart to decipher the code. For example purposes, the tire size P225/60 R 16 97 T is used in the chart. An All Season type tire will also have either M + S, M AND S, or M - S (indicating mud and snow traction) imprinted on the side wall. An Extra or Light Load marking "XL" or "LL" may also be listed on the sidewall. The absence of an "XL" or "LL" marking infers a standard load tire. TIRE IDENTIFICATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 5610 NOTE: * Height (2) ÷ Width (1) = Aspect Ratio. NOTE: ** Consult the tire manufacturer regarding any questions on tire specifications or capabilities. TIRE CHAINS Refer to the owners manual supplied with the vehicle to determine whether the use of tire chains is permitted on this vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 5611 Tires: Description and Operation Spare Tire SPARE TIRE A compact (temporary) spare tire is standard equipment on this vehicle. SRT vehicles and select Export vehicles are equipped with the TIRE FIT tire repair kit as standard equipment in place of a spare tire. It is to be used to repair small punctures in the tire as necessary. A compact spare tire is optional on those select Export Vehicles. The compact spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 80 km/h (50 mph) when using the compact spare tire. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 5612 Tires: Description and Operation Replacement Tires REPLACEMENT TIRES WARNING: Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure. WARNING: In order to maintain the speed capability of the vehicle, replacement tires must have speed ratings equal to or higher than those fitted to the vehicle as original equipment. If tires with lower speed ratings are fitted, the vehicle's handling may be affected and the speed capability of the vehicle may be lowered to the maximum speed capability of the replacement tires. To avoid an accident resulting in severe or fatal injury, consult the tire manufacturer in regards to maximum speed ratings. It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The original equipment tires provide a proper combination of many characteristics such as: - Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability The use of tires smaller than the minimum tire size approved for the vehicle can result in tire overloading and failure. Use tires that have the approved load rating for the vehicle and never overload them. Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure and loss of vehicle control. The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Wear Patterns Tires: Testing and Inspection Tire Wear Patterns TIRE WEAR PATTERNS Under inflation will cause wear on the shoulders of tire. Over inflation will cause wear at the center of tire. Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the other. Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Wear Patterns > Page 5615 Tires: Testing and Inspection Tread Wear Indicators TREAD WEAR INDICATORS Tread wear indicators are molded into the bottom of the tread grooves. When tread depth is 1.6 mm (1/16 in.), the tread wear indicators will appear as a 13 mm (1/2 in.) band (3). Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures Cleaning TIRE CLEANING Before delivery of a vehicle, remove the protective coating on the tires with white sidewalls or raised white letters. To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating away with a soft bristle brush. Steam cleaning may also be used to remove the coating. CAUTION: DO NOT use gasoline, mineral oil, oil-based solvent or a wire brush for cleaning. Tire Inflation Pressures TIRE INFLATION PRESSURES The specified tire pressures have been chosen to provide safe operation, vehicle stability, and a smooth ride. The proper tire pressure specification can be found on the Tire And Loading Information Label provided with the vehicle (usually on the driver's door opening (B-pillar) or rear shut-face of driver's door). A quality air pressure gauge is recommended to check tire air pressure. Tire pressure should be checked cold once per month. Check tire pressure more frequently when the weather temperature varies widely. Tire pressure will decrease when the outdoor temperature drops. After checking the air pressure, replace valve cap finger tight. Inflation pressures specified on the Tire Inflation Pressure Label are always the cold inflation pressure of the tire. Cold inflation pressure is obtained after the vehicle has not been operated for at least 3 hours, or the vehicle is driven less than one mile after being inoperative for 3 hours. Tire inflation pressures may increase from 2 to 6 pounds per square inch (psi) during operation. Do not reduce this normal pressure buildup. Improper inflation can cause: - Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - The vehicle to drift. WARNING: Over or Under inflated tires can affect vehicle handling. The tire can fail suddenly, resulting in loss of vehicle control. Under inflation causes rapid shoulder wear, tire flexing, and can result in tire failure (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 5618 Over inflation causes rapid center wear and loss of the tire's ability to cushion shocks (1). Tire Pressure For High Speed Operation TIRE PRESSURE FOR HIGH SPEED OPERATION Refer to the vehicle's Owners Manual Package. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 5619 Tires: Removal and Replacement TIRE LEAK REPAIRING For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area (1). The tire should be replaced if the puncture is located in the sidewall. Deflate tire completely before attempting to dismount the tire from the wheel. Use a lubricant such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and progressively tighten the five wheel nuts to a torque of 135 Nm (100 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information NUMBER: 22-002-09 GROUP: Wheels/Tires DATE: July 29, 2009 SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome Clad wheels to wheel balancing equipment. MODELS: 2004-2008 (CS) Pacifica 2007 - 2009 (D1) Ram Truck (3500 Pick Up) 2007 - 2010 DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2004 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2009-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2008 - 2010 (JS27) Sebring Convertible 2007 - 2010 (JS41) Sebring/Avenger 2007-2010 (KA) Nitro 2002-2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2008 - 2010 (KK) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005-2010 (ND) Dakota 2007 - 2001 (PM) Caliber 2001 - 2009 (PT) Chrysler PT Cruiser 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2008 - 2010 (RI) Town & Country/Grand Caravan Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 5624 2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005-2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander NOTE: This information applies to any model equipped with Chrome Clad Wheels. DISCUSSION: Models equipped with Chrome Clad wheels require specific piloting on balance equipment to properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones. Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1). SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters, contact Pentastar Service Equipment @ 1-800-223-5623. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5625 Wheels: Specifications SPECIFICATIONS BASE WHEEL SRT4 TORQUE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5626 Wheels: Description and Operation DESCRIPTION All vehicles use either steel or cast aluminum drop center wheels. The original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. Every wheel has raised sections between the rim flanges (1) and drop well (3) called safety humps (2). In case of air loss, these raised sections help hold the tire in position on the wheel until the vehicle can be brought to a safe stop. When being installed on the wheel, initial inflation of the tire forces the tire bead over these raised sections into place. The wheel studs and nuts are designed for specific wheel applications and must be replaced with equivalent parts. Do not use replacement parts of lesser quality or of a substitute design. All aluminum and steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5627 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. WARNING: Replacement with used wheels is not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: Chrysler LLC does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For clarification: Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit (93 degrees Celsius). - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure. - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5628 Wheels: Service and Repair WHEEL AND WHEEL TRIM CARE All wheels and wheel trim, especially aluminum and chrome plated, should be cleaned regularly using mild soap and water to maintain their luster and to prevent corrosion. Wash them with the same soap solution recommended for the body of the vehicle. When cleaning extremely dirty wheels, care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to the wheels. Mopar(R) Tire AND Wheel Cleaner, Mopar(R) Wheel Treatment or Mopar(R) Chrome Cleaner is recommended. Any of the "DO NOT USE" items listed below can damage wheels and wheel trim. DO NOT USE: - Any abrasive cleaner - Any abrasive cleaning pad (such as steel wool) or abrasive brush - Any cleaner that contains an acid which can react with and discolor the chrome surface. Many wheel cleaners contain acids that can harm the wheel surface. - Oven cleaner - A car wash that uses carbide-tipped wheel cleaning brushes or acidic solutions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Hub and Bearing - Description Wheel Bearing: Description and Operation Front Hub and Bearing - Description DESCRIPTION The wheel bearing (5) and hub (3) are pressed into the knuckle (1). The wheel bearing is secured in place using a snap ring. One side of the wheel bearing has an integrated magnetic encoder ring for wheel speed sensor usage as equipped. It is important that the wheel speed sensor magnetic encoder ring (dark band) (3) be positioned to the inside of the knuckle or the wheel speed sensor will not operate correctly. The wheel bearing is a Unit 1 type cartridge bearing that requires no maintenance. The wheel bearing can be serviced separately from the hub. The hub supports the driveline halfshaft outer constant velocity (C/V) joint. Each is splined and meshes in the center of the hub. The outer C/V joint is retained to the hub using a nut. The nut is locked to the outer C/V stub shaft using a cotter pin. The hub has five studs pressed into its flange. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Hub and Bearing - Description > Page 5633 Wheel Bearing: Description and Operation Rear Hub and Bearing - Description DESCRIPTION The rear wheel bearing and wheel mounting hub used on this vehicle are a one-piece sealed unit or hub and bearing assembly. It is permanently lubricated when assembled and is sealed for life. There is no periodic lubrication or maintenance recommended for these units. The hub and bearing (5) is mounted to the trailing link (1). All vehicles have a magnetic encoder integrated into the right rear hub and bearing for speed sense. Vehicles equipped with antilock brakes have a magnetic encoder integrated into both rear hub and bearings. The encoder works with the rear wheel speed sensors to provide wheel speed signal. The sensor mounts by screw to the rear of the hub and bearing. The only serviceable components of the hub and bearing are the wheel mounting studs pressed into the hub. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Hub and Bearing Wheel Bearing: Testing and Inspection Front Hub and Bearing WHEEL BEARING AND HUB NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weeping from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Testing and Inspection Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Hub and Bearing > Page 5636 Wheel Bearing: Testing and Inspection Rear Hub and Bearing HUB AND BEARING NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of periodic maintenance. The following procedure may be used for diagnosing the condition of the wheel bearing and hub. 1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. Rotate the wheel hub checking for resistance or roughness. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the bearing exhibits any of these conditions, the hub and bearing will require replacement. Do not attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must be replaced. Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement. Moderate grease weapage from the bearing is considered normal and should not require replacement of the wheel bearing. To diagnose a bent hub, measure hub runout. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Testing and Inspection Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal Wheel Bearing: Service and Repair Front Hub and Bearing - Removal REMOVAL NOTE: The removal and installation of the wheel bearing and hub from the knuckle is only to be done with the knuckle removed from the vehicle. 1. Remove the steering knuckle from the vehicle. See: Steering/Front Steering Knuckle/Service and Repair/Front Steering Knuckle - Removal 2. Position the knuckle support fixture 9712 as follows: a. For left side knuckles, place the locator block (2) to the left side (4) on the Fixture. The side of the locator block with the angle cut goes downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54 Nm (40 ft. lbs.). b. For right side knuckles, place the locator block (2) to the right side (3) on the Fixture. The side of the locator block with the angle cut goes downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54 Nm (40 ft. lbs.). 3. Install the knuckle in the Fixture as shown, guiding the steering arm (1) to rest on the locator block (3) and the brake caliper mounting bosses on the two Fixture pins (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5639 4. Place the Fixture (3) with knuckle in an arbor press. 5. Position Remover/Installer 9712-2 (2), in the small end of the hub. Lower the arbor press ram (1) and remove the hub from the wheel bearing and knuckle. The bearing race will normally come out of the wheel bearing with the hub as it is pressed out of the bearing. 6. Remove the knuckle from the Fixture and turn it over. 7. Remove the snap ring (2) from the knuckle using an appropriate pair of snap ring pliers (1). 8. Place the knuckle back in the Fixture (3) in the arbor press ram. 9. Place Installer (2) MD-998334, on the outer race of the wheel bearing. Lower the arbor press ram (1) and remove the wheel bearing from the knuckle. 10. Remove the knuckle and tools from arbor press. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5640 11. If the bearing race is still pressed onto the hub, install the Bearing Splitter (5), Special Tool 1130, between the hub flange and the bearing inner race (4). 12. Place the hub, bearing race and Bearing Splitter in an arbor press. The press support blocks must not obstruct the wheel hub while it is being pressed out of the bearing race. 13. Place Remover/Installer 9712-2 (2) in the end of the hub (3). Lower the arbor press ram (1) and remove the hub from the bearing race. NOTE: For installation, See: Front Hub and Bearing - Installation . Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5641 Wheel Bearing: Service and Repair Front Hub and Bearing - Installation INSTALLATION CAUTION: When installing the wheel bearing (1) in the knuckle (2) it is important to place the side of bearing with the wheel speed sensor magnetic encoder ring (dark band) (3) in the knuckle first. Otherwise, the wheel speed sensor will not operate correctly. 1. Wipe the bearing bore of the knuckle clean of any grease or dirt with a clean, dry shop towel. 2. Place the knuckle in an arbor press supporting the knuckle from underneath using Cup 6310-1 (4.) 3. Place the NEW wheel bearing (5) magnetic encoder ring side down (see above Caution) into the bore of the knuckle. Be sure the wheel bearing is placed squarely into the bore. 4. Place Receiver 8498 (3), larger inside diameter end down over the outer race of the wheel bearing. 5. Place Disc 6310-2 (2) into top of Receiver 8498. Lower the arbor press ram (1) and press the wheel bearing into the knuckle until it is bottomed in the bore of the knuckle. 6. Remove the knuckle and tools from the arbor press. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5642 7. Install a NEW snap ring (2) in the knuckle using an appropriate pair of snap ring pliers (1). Make sure the snap ring is fully seated. 8. Place the knuckle in an arbor press. Support the knuckle from underneath using Remover/Installer MB-990799 (3), smaller end up against the wheel bearing inner race. 9. Place the hub (4) in the wheel bearing making sure it is square with the bearing inner race. 10. Position Remover/Installer 9712-2 (2) in the end of the hub. Lower the arbor press ram (1) and press the hub into the wheel bearing until it bottoms. 11. Remove the knuckle and tools from the press. 12. Verify the hub turns smoothly without rubbing or binding. 13. Install the knuckle on the vehicle. See: Steering/Front Steering Knuckle/Service and Repair/Front Steering Knuckle - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5643 Wheel Bearing: Service and Repair Rear Hub and Bearing - Removal REMOVAL NOTE: Before proceeding, See: Suspension/Service Precautions/Vehicle Damage Warnings . 1. Raise and support the vehicle. See: Vehicle Lifting/Service and Repair 2. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly. 3. Remove the disc brake caliper (2) lower guide pin bolt (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5644 CAUTION: When moving rear brake caliper upward, use extreme care not to damage or overextend the flex hose. Damage may occur. 4. Rotate the caliper upward hinging off the upper guide pin bolt. Rotate the caliper upward just enough to allow brake rotor removal. Hang the caliper assembly in this position using wire or a bungee cord. 5. Remove any clips (2) retaining the brake rotor (3) to the wheel mounting studs. 6. Slide the brake rotor (3) off the hub and bearing (1). 7. Remove the screw (1) fastening the wheel speed sensor head (3) in the rear of the hub and bearing (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5645 8. Remove the four bolts (1) securing the hub and bearing (2) to the trailing link. 9. Remove the hub and bearing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5646 Wheel Bearing: Service and Repair Rear Hub and Bearing - Installation FRONT-WHEEL-DRIVE NOTE: If equipped, make sure the wheel speed sensor mount on the rear of the hub and bearing is directed toward the front of the vehicle. 1. Position the hub and bearing on the brake support plate and trailing link. 2. Install the four bolts (1) securing the hub and bearing (2) to the trailing link. Tighten the bolts to 105 Nm (77 ft. lbs.). NOTE: Before installing the wheel speed sensor head (3) into the rear of the hub and bearing (2), inspect the O-ring seal to make sure it is not dislodged, split, cut or damaged in any way. Replace the O-ring as necessary. 3. If equipped with a wheel speed sensor, install the wheel speed sensor head (3) into the rear of the hub and bearing (2). 4. If equipped with a wheel speed sensor, install the wheel speed sensor head mounting screw (1). Tighten the screw to 10 Nm (89 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5647 5. Slide the brake rotor (3) over the parking brake shoes and onto the hub and bearing (1). 6. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 7. Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 60 Nm (44 ft. lbs.). 8. Install tire and wheel assembly (1) See: Service and Repair/Removal and Replacement/Tires and Wheels - Installation. Install and tighten wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 9. Lower the vehicle. 10. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving it. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Wheel Cover - Removal Wheel Cover: Service and Repair Wheel Cover - Removal REMOVAL 1. Raise and support the vehicle so that tire and wheel assembly clears ground level. See: Vehicle Lifting/Service and Repair CAUTION: When removing the bolt-on wheel cover, do not attempt to pry the wheel cover off the wheel. It is held on by the wheel mounting nuts. 2. Remove the five wheel mounting (lug) nuts (3) from the wheel studs. While removing the nuts, hold the wheel cover (2) in place so it doesn't fall off when the last nut is removed. 3. Remove the wheel cover (2) using care not to let the tire and wheel assembly (1) fall off the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair > Wheel Cover - Removal > Page 5652 Wheel Cover: Service and Repair Wheel Cover - Installation INSTALLATION WARNING: Installing wheels without good metal-to-metal contact with the mounting surface could cause loosening of the wheel mounting (lug) nuts. This could adversely affect the safety and handling of the vehicle. NOTE: Never use oil or grease on studs or wheel mounting (lug) nuts. 1. With the tire and wheel assembly (1) positioned on the wheel studs without the wheel mounting (lug) nuts installed, align the valve notch in the wheel cover with the valve stem on the wheel and install the wheel cover over the studs. NOTE: Always use the original (OEM) style wheel mounting (lug) nuts. Do not use replacement parts of lesser quality or substitute design. 2. Install and lightly snug all five wheel mounting (lug) nuts (3) Do not tighten at this time. 3. Lower the vehicle. 4. Progressively tighten all wheel mounting (lug) nuts in the proper sequence shown. Tighten the nuts to a final torque of 135 Nm (100 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front Suspension Axle Nut: Specifications Front Suspension AXLE NUT Hub Nut................................................................................................................................................ ....................................................244 Nm (180 ft.lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front Suspension > Page 5658 Axle Nut: Specifications Rear Suspension AXLE NUT Hub Nut................................................................................................................................................ ....................................................245 Nm (181 ft.lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Mounting (Lug) Nut.................................................................................................................... ..................................................135 Nm (100 ft.lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal Wheel Fastener: Service and Repair Wheel Stud - Removal Front REMOVAL NOTE: Use the following procedure to remove one of five studs on one wheel hub. 1. Access and remove front brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal CAUTION: Do not hammer wheel mounting studs out of the hub. Damage to the wheel bearing will occur, leading to premature bearing failure. 2. Install Remover 8677 (3) on the hub flange (1) and wheel stud (2). 3. Tighten the Remover, pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of the stud is past the flange, remove the Remover from the hub. 4. Remove the stud from the hub flange. Rear REMOVAL NOTE: Use the following procedure to remove one of five studs on one wheel hub. 1. If equipped with rear disc brakes, access and remove brake rotor. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal 2. If equipped with rear drum brakes, access and remove brake drum. See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement/Removal CAUTION: Do not hammer wheel mounting studs out of the hub. Damage to the wheel bearing will occur, leading to premature bearing failure. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 5664 3. Install Remover 8677 (1) on the hub flange (2) and wheel stud (3). 4. Rotate the hub around until an open spot is found directly behind the wheel stud. 5. Tighten the Remover, pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of the stud is past the flange, remove the Remover from the hub. 6. Remove the stud from the hub flange. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 5665 Wheel Fastener: Service and Repair Wheel Stud - Installation Front INSTALLATION NOTE: Use the following procedure to install one of five studs on one wheel hub. 1. Install the NEW wheel mounting stud in the flange of the hub (2) from the rear. 2. Install several washers (1) and a standard wheel mounting (lug) nut (3) on the stud (4). Install the mounting nut so that the flat side of the nut is against the washers to eliminate any binding. 3. Tighten the wheel mounting nut. This will pull the wheel mounting stud into the hub flange. When the head of the stud is fully seated against the rear of the hub flange, remove the wheel mounting nut and washers. 4. Install the brake rotor and all components previously removed to access it. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation Rear INSTALLATION NOTE: Use the following procedure to install one of five studs on one wheel hub. 1. Install the NEW wheel mounting stud in the flange of the hub (2) from the rear. 2. Install several washers (1) and a standard wheel mounting (lug) nut (3) on the stud (4). Install the mounting nut so that the flat side of the nut is against the washers to eliminate any binding. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 5666 3. Tighten the wheel mounting nut. This will pull the wheel mounting stud into the hub flange. When the head of the stud is fully seated against the rear of the hub flange, remove the wheel mounting nut and washers. 4. If equipped with rear disc brakes, install the brake rotor and all components previously removed to access it. See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation 5. If equipped with rear drum brakes, install the brake drum and tire and wheel assembly. See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement/Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation > Accumulator - Description Accumulator HVAC: Description and Operation Accumulator - Description DESCRIPTION To protect the A/C compressor from any liquid slugging, an A/C accumulator (1) is used in this A/C system to retain any refrigerant that may exit from the evaporator in a liquid state. The A/C accumulator is mounted below the engine compartment behind the right side of the front fascia. A band and mounting bracket (2) secures the A/C accumulator to the right front frame rail and the connections are sealed by use of metal gaskets (3) and rubber O-rings (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation > Accumulator - Description > Page 5672 Accumulator HVAC: Description and Operation Accumulator - Operation OPERATION NOTE: Typical A/C accumulator shown. Refrigerant enters the A/C accumulator (1) mostly as a low pressure vapor through the inlet tube (2). Any liquid, oil-laden refrigerant falls to the bottom of the canister, which acts as a separator. A desiccant bag (3) is mounted inside the accumulator canister to absorb any moisture which may have entered and become trapped within the refrigerant system. A filter (4) is also mounted inside the canister to trap any foreign material that may have entered the refrigerant system during assembly. The low pressure vapor exits the A/C accumulator through the outlet tube (5). NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C accumulator has no serviceable parts except for the O-ring seals and gaskets. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C accumulator is removed and installed. The A/C accumulator cannot be repaired and must be replaced if found to be leaking or damaged, or if an internal failure of the A/C compressor has occurred. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Accumulator - Removal Accumulator HVAC: Service and Repair Accumulator - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant systemSee: Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Remove the right front wheel See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Removal. 5. Remove the three push-pin retainers (1) and three screws (2) that secure the front portion of the right front wheelhouse splash shield (3) to body (4) and position the front of the wheelhouse splash shield out of the way to gain access to the A/C accumulator. 6. Remove the nut (7) that secures the lower A/C suction line (8) to the accumulator outlet tube (9) and disconnect the suction line from the accumulator tube. 7. Remove the bolt (5) and retaining band (6) that secure the A/C accumulator to the mounting bracket (10). 8. Remove the nut (3) that secures the upper A/C suction line (2) to the accumulator inlet tube (4) and disconnect the suction line from the accumulator tube. 9. If necessary remove the accumulator mounting bracket from the body. 10. Remove and discard the O-ring seals and gaskets and install plugs in, or tape over the opened refrigerant line fittings and the accumulator ports. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Accumulator - Removal > Page 5675 Accumulator HVAC: Service and Repair Accumulator - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: The A/C accumulator must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C accumulator can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Service and Repair/Refrigerant Oil Level . NOTE: If only the A/C accumulator is being replaced, add 30 milliliters (1.0 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. 1. If removed, install the accumulator mounting bracket (10). Tighten the retaining bolts to 15 Nm (11 ft. lbs.). 2. Remove the tape or plugs from all of the opened refrigerant line fittings and the accumulator ports. 3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the suction line and accumulator fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the upper A/C suction line (2) to the accumulator inlet tube (4) and install the retaining nut (3). Tighten the nut to 5 Nm (44 in. lbs.). 5. Install the retaining band (6) and bolt (5) that secure the A/C accumulator (1) to the mounting bracket. Tighten the bolt to 8 Nm (71 in. lbs.). 6. Connect the lower A/C suction line (8) to the accumulator outlet tube (9) and install the retaining nut (7). Tighten the nut to 5 Nm (44 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Accumulator - Removal > Page 5676 7. Reposition the front of the right front wheel house splash shield (3) to the body (4) and install the three push-pin retainers (1) and the three screws (2). Tighten the screws securely. 8. Install the right front wheel See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. 9. Lower the vehicle. 10. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 11. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 12. If the A/C accumulator is being replaced, add 30 milliliters (1.0 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Service and Repair/Refrigerant Oil Level. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 13. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Air Door Actuator / Motor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 5681 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 5682 Air Door Actuator / Motor: Diagrams Connector - (INSTRUMENT PANEL) 6 WAY ACTUATOR-RECIRCULATION DOOR - (INSTRUMENT PANEL) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Recirculation Door Actuator - Description Air Door Actuator / Motor: Description and Operation Recirculation Door Actuator - Description DESCRIPTION The recirculation door actuator (1) is a reversible, 12 volt direct current (DC) servo motor, which is connected directly to the pivot shaft lever of the recirculation-air door. The recirculation door actuator is located on the right side of the HVAC air inlet housing. The recirculation door actuator is contained within a black molded plastic housing with an integral wire connector receptacle (2), an output shaft with splines (3) that connect it to the recirculation door and three integral mounting tabs (4) that allow the actuator to be secured to the air inlet housing. The recirculation door actuator does not require mechanical indexing to the recirculation-air door, as it is electronically calibrated by the A/C-heater control. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Recirculation Door Actuator - Description > Page 5685 Air Door Actuator / Motor: Description and Operation Recirculation Door Actuator - Operation OPERATION The recirculation door actuator is connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the instrument panel wire harness. The recirculation door actuator can move the recirculation-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the recirculation-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the recirculation-air door moves in the opposite direction. Once the A/C-heater control makes the voltage to both connections high or both connections low, the recirculation-air door stops and will not move. The recirculation door actuator cannot be adjusted or repaired and it must be replaced if inoperative or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Recirculation Door Actuator - Removal Air Door Actuator / Motor: Service and Repair Recirculation Door Actuator - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Illustration shown with instrument panel removed for clarity. NOTE: LHD model shown. RHD model similar. 1. Disconnect and isolate the negative battery cable. 2. Remove the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Removal. 3. Reach through the glove box opening in the instrument panel and remove the screws (1) that secure the recirculation door actuator (2) to the right side of the HVAC air inlet housing (3). 4. Disconnect the wire harness connector (4) from the recirculation door actuator and remove the actuator. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Recirculation Door Actuator - Removal > Page 5688 Air Door Actuator / Motor: Service and Repair Recirculation Door Actuator - Installation INSTALLATION NOTE: Illustrations shown with instrument panel removed for clarity. NOTE: LHD model shown. RHD model similar. 1. Position the recirculation door actuator (1) to the right side of the HVAC air inlet housing (2). 2. Install the recirculation door actuator onto the air inlet housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the recirculation door pivot shaft adapter (4). 3. Install the screws (1) that secure the recirculation door actuator (2) to the air inlet housing (3). Tighten the screws to 2 Nm (17 in. lbs.). 4. Connect the instrument panel wire harness connector (4) to the recirculation door actuator. 5. Install the glove box binSee: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Installation. 6. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Door Cable - Removal Air Door Cable: Service and Repair Mode Door Cable - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Illustration shown with instrument panel removed for clarity. NOTE: LHD model shown. RHD model similar. 1. Disconnect and isolate the negative battery cable. 2. Remove the shifter bezel and instrument panel center bezel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. NOTE: To aid in reinstallation, note the installed position of the mode control cable to the A/C-heater control prior to removal of the cable. 3. Disconnect the mode control cable from the A/C-heater control See: Control Assembly/Service and Repair/A/C and Heater Control - Removal. 4. On LHD models, remove the glove box See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Removal. 5. On LHD models equipped with beverage cooler, remove the instrument panel top cover, end caps, upper IP cover, radio, shifter housing and the fasteners that secure the top and passenger side of the IP base panel to the instrument panel support See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. Position the passenger side of the base panel slightly rearward to gain access to the metal retaining clip (1) on the right side of the HVAC air distribution housing (3). 6. Disengage the metal retaining clip (1) that secures the mode control cable (2) to the right side of the HVAC air distribution housing (3). NOTE: To aid in reinstallation, note the position of the mode control cable as it passes through the instrument panel support prior to removal of the cable. 7. Disconnect the mode control cable from the mode door cam (4) and remove the cable from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Door Cable - Removal > Page 5693 Air Door Cable: Service and Repair Mode Door Cable - Installation INSTALLATION NOTE: Illustration shown with instrument panel removed for clarity. NOTE: LHD model shown. RHD model similar. 1. Position the mode control cable (2) to the right side of the HVAC air distribution housing (3) through the opening in the instrument panel support. 2. Connect the mode control cable to the mode door cam (4). 3. Engage the metal retaining clip (1) to the right side of the HVAC air distribution housing. Make sure the retaining clip is fully engaged to the housing. 4. Connect the mode door control cable to the A/C-heater control See: Control Assembly/Service and Repair/A/C and Heater Control - Installation. 5. Visually verify the mode door cam moves from the full defrost position to the full panel position and then back to the full defrost position using the mode control knob on the A/C-heater control. If OK, go to step 10. If not OK, proceed to step 6. CAUTION: Failure to adjust the mode control cable when required can result in operating modes not being properly obtained. 6. Disengage the mode control cable from the metal retaining clip located on the right side of the HVAC housing. 7. Turn the mode control knob on the A/C-heater control to the full defrost position. 8. Reach behind the instrument panel and turn the mode door cam clockwise until it stops in the full defrost position and engage the mode control cable to the metal retaining clip. Make sure the cam is in the full defrost position and that the cable is fully engaged to the retaining clip. 9. Verify the mode door cam moves from the full defrost position to the full panel position and then back to the full defrost position as selected with the mode control knob on the A/C-heater control. If not, repeat steps 6 thru 9. 10. On LHD models equipped with beverage cooler, reposition the passenger side of the IP base panel to the instrument panel support and install related components See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Installation. 11. On LHD models, install the glove box See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Installation. 12. Install the instrument panel center bezel and shifter bezel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 13. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Door Cable - Removal > Page 5694 Air Door Cable: Service and Repair Temperature Door Cable - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Illustration shown with instrument panel removed for clarity. NOTE: LHD model shown. RHD model similar. 1. Disconnect and isolate the negative battery cable. NOTE: To aid in reinstallation, note the installed position of the temperature control cable to the A/C-heater control prior to removal of the cable. 2. Remove the instrument panel center bezel and disconnect the temperature control cable from the A/C-heater control See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel Removal. 3. On RHD models, remove the glove box See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Removal. 4. Disengage the metal retaining clip (1) that secures the temperature control cable (2) from the left side of the HVAC air distribution housing (3). NOTE: To aid in reinstallation, note the position of the temperature control cable as it passes through the instrument panel support prior to removal of the cable. 5. Disconnect the temperature control cable from the blend door pivot lever (4) and remove the cable from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Door Cable - Removal > Page 5695 Air Door Cable: Service and Repair Temperature Door Cable - Installation INSTALLATION NOTE: Illustration shown with instrument panel removed for clarity. NOTE: LHD model shown. RHD model similar. 1. Position the temperature control cable (2) to the left side of the HVAC air distribution housing (3) through the opening in the instrument panel support. 2. Connect the temperature control cable to the blend door pivot lever (4). 3. Engage the metal retaining clip (1) to the left side of the air distribution housing. Make sure the retaining clip is fully engaged to the housing. 4. Connect the temperature door control cable to the A/C-heater control and install the instrument panel center bezel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel Installation. 5. Visually verify that the blend door pivot lever moves from the full hot position to the full cold position and then back to the full hot position using the temperature control knob on the A/C-heater control. If OK, go to step 10. If not OK, proceed to step 6. CAUTION: Failure to adjust the temperature control cable can result in full heating or cooling capabilities not being obtained. 6. Disengage the temperature control cable from the metal retaining clip located on the left side of the HVAC housing. 7. Turn the temperature control knob on the A/C-heater control to the full hot position. 8. Reach behind the instrument panel and move the blend door pivot lever forward until it stops in the full hot position and engage the temperature control cable to the metal retaining clip. Make sure the lever is in the full hot position and that the cable is fully engaged to the retaining clip. 9. Verify that the blend door pivot lever moves from the full hot position to the full cold position and then back to the full hot position, as selected with the temperature control knob on the A/C-heater control. If not, repeat steps 6 thru 9. 10. On RHD models, install the glove box See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Installation. 11. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal Air Duct: Service and Repair Defroster Duct - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: LHD model shown. RHD model similar. NOTE: Illustration shown with instrument panel removed from vehicle for clarity. 1. Remove the instrument panel top coverSee: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Removal. 2. Disconnect the left demister duct (7) and the right demister duct (5) from the defroster duct (2). 3. Remove the two screws (3) that secure the defroster duct to the defroster duct support (4). 4. Remove the two screws (1) that secure the defroster duct support to the instrument panel (6) and position the support out of the way. 5. Remove the defroster duct from the instrument panel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 5700 Air Duct: Service and Repair Defroster Duct - Installation INSTALLATION NOTE: LHD model shown. RHD model similar. NOTE: Illustration shown with instrument panel removed from vehicle for clarity. 1. Position the defroster duct (2) to the front of the instrument panel (6). 2. Reposition the defroster duct support (4) to the instrument panel and install the two retaining screws (1). Tighten the screws to 3 Nm (27 in. lbs.). 3. Install the two screws (3) that secure the defroster duct to the defroster duct support. Tighten the screws to 2.2 Nm (20 in. lbs.). 4. Connect the left demister duct (7) and the right demister duct (5) to the defroster duct. 5. Install the instrument panel top cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 5701 Air Duct: Service and Repair Floor Distribution Duct - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in possible serious or fatal injury. RIGHT FRONT FLOOR DUCT NOTE: LHD model shown. RHD model similar. 1. Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Removal. 2. Disconnect the right floor duct (1) from the right side of the HVAC housing (2) and remove the duct. LEFT FRONT FLOOR DUCT NOTE: Illustration shown with instrument panel removed for clarity. NOTE: LHD model shown. RHD model similar. 1. On LHD models, remove the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 2. On RHD models, remove the instrument panel cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Removal. 3. Remove the screw that secures the left floor distribution duct (1) to the left side of the HVAC housing (2) and disconnect the duct from the housing outlet. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 5702 REAR FLOOR DISTRIBUTION DUCTS 1. Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Removal. 2. Remove the rear seat floor ducts (refer to REAR SEAT FLOOR DUCTS). 3. Disconnect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as required from the HVAC housing (3) and remove the duct(s). REAR SEAT FLOOR DUCTS NOTE: Right side rear floor duct shown. Left side duct similar. NOTE: LHD model shown. RHD model similar. 1. Remove the center floor console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal. 2. Remove the front seat from the side of the vehicle being serviced See: Body and Frame/Seats/Service and Repair/Seat - Removal. 3. Pull the carpet back to gain access to the rear seat floor duct (2) See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Carpet - Removal. 4. Remove the screw (1) and disengage the retainer that secures the rear seat floor duct to the floor support (4). 5. Disconnect the rear seat floor duct from the rear floor distribution duct (3) and remove the rear seat duct(s). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 5703 Air Duct: Service and Repair Floor Distribution Duct - Installation INSTALLATION RIGHT FRONT FLOOR DUCT NOTE: LHD model shown. RHD model similar. 1. Connect the right front floor duct (1) to the right side of the HVAC housing (2). Make sure the duct is fully engaged to the housing. 2. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. LEFT FRONT FLOOR DUCT NOTE: Illustration shown with instrument panel removed for clarity. NOTE: LHD model shown. RHD model similar. 1. Connect the left front floor duct (1) to the left side of the HVAC housing (2). Make sure the duct is fully engaged to the housing. 2. Install the screw that secures the left front floor duct to the left side of the HVAC housing. Tighten the screw to 2 Nm (17 in. lbs.). 3. On LHD models, install the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 4. On RHD models, install the instrument panel cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Installation. REAR FLOOR DISTRIBUTION DUCTS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 5704 1. Connect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as required to the HVAC housing (3). Make sure the ducts are fully engaged to the housing. 2. Install the rear seat floor ducts (refer to REAR SEAT FLOOR DUCTS). 3. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. REAR SEAT FLOOR DUCTS NOTE: Right side rear floor duct shown. Left side duct similar. NOTE: LHD model shown. RHD model similar. 1. Connect the rear seat floor duct (2) to the rear floor distribution duct (3). Make sure the ducts are fully engaged to each other. 2. Engage the retainer that secures the rear seat floor duct to the floor support (4) and install the retaining screw (1). Tighten the screw to 2.2 Nm (20 in. lbs.). 3. Reinstall the carpet See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Carpet - Installation. 4. Install the front seat to the side of the vehicle being serviced See: Body and Frame/Seats/Service and Repair/Seat - Installation. 5. Install the center floor console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 5705 Air Duct: Service and Repair Defroster Duct - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: LHD model shown. RHD model similar. NOTE: Illustration shown with instrument panel removed from vehicle for clarity. 1. Remove the instrument panel top coverSee: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Removal. 2. Disconnect the left demister duct (7) and the right demister duct (5) from the defroster duct (2). 3. Remove the two screws (3) that secure the defroster duct to the defroster duct support (4). 4. Remove the two screws (1) that secure the defroster duct support to the instrument panel (6) and position the support out of the way. 5. Remove the defroster duct from the instrument panel. Defroster Duct - Installation INSTALLATION NOTE: LHD model shown. RHD model similar. NOTE: Illustration shown with instrument panel removed from vehicle for clarity. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 5706 1. Position the defroster duct (2) to the front of the instrument panel (6). 2. Reposition the defroster duct support (4) to the instrument panel and install the two retaining screws (1). Tighten the screws to 3 Nm (27 in. lbs.). 3. Install the two screws (3) that secure the defroster duct to the defroster duct support. Tighten the screws to 2.2 Nm (20 in. lbs.). 4. Connect the left demister duct (7) and the right demister duct (5) to the defroster duct. 5. Install the instrument panel top cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Installation. Floor Distribution Duct - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in possible serious or fatal injury. RIGHT FRONT FLOOR DUCT NOTE: LHD model shown. RHD model similar. 1. Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Removal. 2. Disconnect the right floor duct (1) from the right side of the HVAC housing (2) and remove the duct. LEFT FRONT FLOOR DUCT NOTE: Illustration shown with instrument panel removed for clarity. NOTE: LHD model shown. RHD model similar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 5707 1. On LHD models, remove the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 2. On RHD models, remove the instrument panel cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Removal. 3. Remove the screw that secures the left floor distribution duct (1) to the left side of the HVAC housing (2) and disconnect the duct from the housing outlet. REAR FLOOR DISTRIBUTION DUCTS 1. Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Removal. 2. Remove the rear seat floor ducts (refer to REAR SEAT FLOOR DUCTS). 3. Disconnect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as required from the HVAC housing (3) and remove the duct(s). REAR SEAT FLOOR DUCTS NOTE: Right side rear floor duct shown. Left side duct similar. NOTE: LHD model shown. RHD model similar. 1. Remove the center floor console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console - Removal. 2. Remove the front seat from the side of the vehicle being serviced See: Body and Frame/Seats/Service and Repair/Seat - Removal. 3. Pull the carpet back to gain access to the rear seat floor duct (2) See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Carpet - Removal. 4. Remove the screw (1) and disengage the retainer that secures the rear seat floor duct to the floor support (4). 5. Disconnect the rear seat floor duct from the rear floor distribution duct (3) and remove the rear seat duct(s). Floor Distribution Duct - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 5708 INSTALLATION RIGHT FRONT FLOOR DUCT NOTE: LHD model shown. RHD model similar. 1. Connect the right front floor duct (1) to the right side of the HVAC housing (2). Make sure the duct is fully engaged to the housing. 2. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. LEFT FRONT FLOOR DUCT NOTE: Illustration shown with instrument panel removed for clarity. NOTE: LHD model shown. RHD model similar. 1. Connect the left front floor duct (1) to the left side of the HVAC housing (2). Make sure the duct is fully engaged to the housing. 2. Install the screw that secures the left front floor duct to the left side of the HVAC housing. Tighten the screw to 2 Nm (17 in. lbs.). 3. On LHD models, install the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 4. On RHD models, install the instrument panel cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Installation. REAR FLOOR DISTRIBUTION DUCTS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 5709 1. Connect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as required to the HVAC housing (3). Make sure the ducts are fully engaged to the housing. 2. Install the rear seat floor ducts (refer to REAR SEAT FLOOR DUCTS). 3. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. REAR SEAT FLOOR DUCTS NOTE: Right side rear floor duct shown. Left side duct similar. NOTE: LHD model shown. RHD model similar. 1. Connect the rear seat floor duct (2) to the rear floor distribution duct (3). Make sure the ducts are fully engaged to each other. 2. Engage the retainer that secures the rear seat floor duct to the floor support (4) and install the retaining screw (1). Tighten the screw to 2.2 Nm (20 in. lbs.). 3. Reinstall the carpet See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Carpet - Installation. 4. Install the front seat to the side of the vehicle being serviced See: Body and Frame/Seats/Service and Repair/Seat - Installation. 5. Install the center floor console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Center Console Installation. Instrument Panel Duct - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Illustrations shown with instrument panel removed from vehicle for clarity. LEFT AND RIGHT SIDE DUCT Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 5710 NOTE: The left and right side instrument panel ducts are serviced only as an assembly with the left or right side demister duct. NOTE: LHD model shown. RHD model similar. 1. Remove the instrument panel top coverSee: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Removal. 2. Disconnect the left side demister hose (3) and right side demister hose (5) from the defroster duct (4). 3. Remove the screws (2) that secure each demister duct (1 and 6) to the instrument panel support. 4. Remove the push-pin fastener (8) that secures each instrument panel duct (7 and 10) to the instrument panel support. 5. Disconnect the left and right side instrument panel ducts from the center duct (9). 6. Remove the each instrument panel duct and demister duct as an assembly from the instrument panel. CENTER DUCT NOTE: LHD model shown. RHD model similar. 1. Remove the left and right side instrument panel and demister ducts (1 and 2) (refer to LEFT AND RIGHT SIDE DUCT ). 2. Remove the two screws (3) that secure the center instrument panel duct (4) to the instrument panel support. 3. Rotate and tilt the center duct as necessary to remove it from the instrument panel. Instrument Panel Duct - Installation INSTALLATION NOTE: Illustrations shown with instrument panel removed from vehicle for clarity. LEFT AND RIGHT SIDE DUCT Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 5711 NOTE: The left and right side instrument panel ducts are serviced only as an assembly with the left or right side demister duct. NOTE: LHD model shown. RHD model similar. 1. Position the left and right side instrument panel ducts (7 and 10) and the left and right side demister ducts (1 and 6) onto the top of the instrument panel as assemblies. 2. Connect the left and right side instrument panel ducts to the center duct (9). Make sure the ducts are fully engaged to each other. 3. Install the push-pin fastener (8) that secures each instrument panel duct to the instrument panel support. 4. Install the screws (2) that secure each demister duct to the instrument panel support. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Connect the left and right side demister hoses (3 and 5) to the defroster duct (4). Make sure the hoses are fully engaged to the defroster and demister ducts. 6. Install the instrument panel top cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Installation. CENTER DUCT NOTE: LHD model shown. RHD model similar. 1. Position the center instrument panel duct (2) onto the top of instrument panel. Rotate and tilt the duct as necessary. 2. Install the two screws (3) that secure the center duct to the instrument panel support. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Install the left and right side instrument panel and demister ducts (1 and 2) (refer to LEFT AND RIGHT SIDE DUCT ). Instrument Panel Demister Duct - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 5712 discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The left and right side demister ducts are serviced only as an assembly with the left or right side instrument panel duct. NOTE: Illustration shown with instrument panel removed from vehicle for clarity. NOTE: LHD model shown. RHD model similar. 1. Remove the instrument panel top coverSee: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Removal. 2. Disconnect the left side demister hose (3) and right side demister hose (5) from the defroster duct (4). 3. Remove the screws (2) that secure each demister duct (1 and 6) to the instrument panel support. 4. Remove the push-pin fastener (8) that secures each instrument panel duct (7 and 10) to the instrument panel support. 5. Disconnect the left and right side instrument panel ducts from the center duct (9). 6. Remove the each demister duct and instrument panel duct as an assembly from the instrument panel. Instrument Panel Demister Duct - Installation INSTALLATION NOTE: The left and right side demister ducts are serviced only as an assembly with the left or right side instrument panel duct. NOTE: Illustration shown with instrument panel removed from vehicle for clarity. NOTE: LHD model shown. RHD model similar. 1. Position the left and right side demister ducts (1 and 6) and the left and right side instrument panel ducts (7 and 10) onto the top of the instrument panel as assemblies. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 5713 2. Connect the left and right side instrument panel ducts to the center duct (9). Make sure the ducts are fully engaged to each other. 3. Install the push-pin fastener (8) that secures each instrument panel duct to the instrument panel support. 4. Install the screws (2) that secure each demister duct to the instrument panel support. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Connect the left and right side demister hoses (3 and 5) to the defroster duct (4). Make sure the hoses are fully engaged to the defroster and demister ducts. 6. Install the instrument panel top cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Description and Operation Air Register: Description and Operation DESCRIPTION NOTE: LHD model shown. RHD model similar. There is one defroster air outlet (2) located on the top of the instrument panel (1). The airflow from the defroster outlet is directed by fixed vanes in the outlet and cannot be adjusted. The defroster air outlet is not serviceable from the instrument panel cover. There are two side window demister air outlets (4). One located on each end of the instrument panel top cover. The airflow from the side window demister air outlets is directed by fixed vanes in the outlets and cannot be adjusted. The side window demister air outlets are not serviceable from the instrument panel top cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Removal. There are four rectangular instrument panel air outlets (5). One air outlet is located near each outboard end of the instrument panel facing the rear of the vehicle and two air outlets are located at the top of the instrument panel center bezel. Each of the instrument panel air outlets contain movable vanes that can direct or shut off the flow of the conditioned air leaving each of the instrument panel outlets. The driver and passenger side air instrument panel air outlets can be serviced separately. The center outlets are only serviced with the center bezel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. Some models with A/C are equipped with a cooled beverage storage bin located in the instrument panel. Vehicles so equipped have an outlet, which, when opened with the A/C on, allows cooled air to flow into the bin. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet - Removal Air Register: Service and Repair Air Outlet - Removal Beverage Cooler BEVERAGE COOLER NOTE: LHD model shown. RHD model similar. 1. Remove the instrument panel top cover (1)See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Removal. 2. Disconnect the hose (2) from the beverage cooler outlet (3). 3. To disengage the four retaining tabs (4), slide the beverage cooler outlet toward the center of the cover and remove the outlet. Instrument Panel INSTRUMENT PANEL NOTE: LHD driver side air outlet shown. RHD and passenger side outlet similar. NOTE: Take the proper precautions to protect the faces of the instrument panels and covers from cosmetic damage while performing this procedure. 1. Depending on the air outlet being serviced, remove the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal or the IP base panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 2. Place the steering column opening cover or IP base panel on a workbench. 3. Remove the four screws (1) that secure the air outlet (2) to the cover or panel (3) and remove the outlet. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet - Removal > Page 5719 Air Register: Service and Repair Air Outlet - Installation Beverage Cooler BEVERAGE COOLER NOTE: LHD model shown. RHD model similar. 1. Position the beverage cooler outlet (3) to the top of the storage bin and engage the four retaining tabs (4) by sliding the outlet toward the center of the instrument panel top cover (1). Make sure the tabs are fully engaged. 2. Connect the hose (2) to the beverage cooler outlet. 3. Install the instrument panel top cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Installation. Instrument Panel INSTRUMENT PANEL NOTE: LHD driver side air outlet shown. RHD and passenger side outlet similar. NOTE: Take the proper precautions to protect the faces of the instrument panels and covers from cosmetic damage while performing this procedure. NOTE: If the foam seal on the air outlet is deformed or damaged, it must be replaced. 1. Position the air outlet (2) onto the steering column opening cover or IP base panel (3) and install the four screws (1). Tighten the screws to 2 Nm (17 in. lbs.). NOTE: Make sure the foam seal on the air outlet is properly positioned into the IP duct to prevent air leaks and excessive noise during Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet - Removal > Page 5720 A/C-heater operation. 2. Depending on the outlet being serviced, install the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation or the IP base panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5724 Ambient Temperature Sensor / Switch HVAC: Diagrams Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-AMBIENT AIR TEMPERATURE - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations Blower Motor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 5728 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5734 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5735 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5736 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5737 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5738 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5739 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5740 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5741 Blower Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5742 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5743 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5744 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5745 Blower Motor: Connector Views Connector - (INSTRUMENT PANEL) 2 WAY MOTOR-BLOWER - (INSTRUMENT PANEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Description Blower Motor: Description and Operation Description DESCRIPTION The blower motor (1) is used to control the velocity of air moving through the HVAC housing by spinning the blower wheel (2) within the HVAC air inlet housing at the selected speed. The blower motor is a 12-volt, direct current (DC) motor mounted within a plastic housing with an integral wire harness connector (3) and three mounting tabs (4). The squirrel cage-type blower wheel is secured to the blower motor shaft and is positioned within the air inlet housing on the passenger side of the HVAC housing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Description > Page 5748 Blower Motor: Description and Operation Operation OPERATION The blower motor is used to control the velocity of air moving through the HVAC housing by spinning the blower wheel within the HVAC air inlet housing at the selected speed. The blower motor will operate whenever the ignition switch is in the Run position and the blower motor control is in any position except Off. The blower motor receives battery current through the totally integrated power module (TIPM) whenever the ignition switch is in the Run position. Blower motor speed is controlled by regulating the ground path through or around the blower motor resistor and through the blower motor control located within the A/C-heater control. The blower motor can be accessed for service from underneath the instrument panel. NOTE: The blower motor is supplied with a 12V feed from the TIPM, through the blower motor resistor, whenever the ignition switch is in the RUN position. Due to an open circuit condition within the blower motor control switch the TIPM is UNABLE to detect an OPEN circuit for the blower motor. The blower motor control system is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The blower motor and blower motor wheel are factory balanced as an assembly and cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Page 5749 Blower Motor: Testing and Inspection BLOWER MOTOR WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The blower motor is supplied with a 12V feed from the TIPM, through the blower motor resistor, whenever the ignition switch is in the RUN position. Due to an open circuit condition within the blower motor control switch the TIPM is UNABLE to detect an OPEN circuit for the blower motor. To determine if an open condition exists within the blower motor circuit wiring, it is necessary to disconnect the negative battery cable and check for continuity within the blower motor circuits using an ohmmeter. See Wiring Information for circuit descriptions and diagrams. OPERATION Possible causes of an inoperative blower motor include: - Open fuse - Inoperative blower motor resistor - Inoperative blower motor switch - Inoperative blower motor - Inoperative blower motor circuit wiring or wire harness connectors NOISE To determine if the blower motor is the source of the noise, simply switch the blower motor from Off to On. To verify that the blower motor is the source of the noise, unplug the blower motor wire harness connector and operate the heater-A/C system. If the noise goes away, possible causes include: - Foreign material on fresh air inlet screen - Foreign material in blower wheel - Foreign material in HVAC housing - Improper blower motor mounting - Deformed or damaged blower wheel - Worn blower motor bearings or brushes VIBRATION Possible causes of a blower motor vibration include: - Improper blower motor mounting - Foreign material in blower wheel - Deformed or damaged blower wheel - Worn blower motor bearings Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal Blower Motor: Service and Repair Removal REMOVAL NOTE: The blower motor is located on the bottom of the passenger side of the HVAC housing. The blower motor can be removed from the vehicle without having to remove the HVAC housing. NOTE: LHD model shown. RHD model similar. 1. Disconnect and isolate the negative battery cable. 2. If equipped, remove the silencer from below the passenger side of the instrument panel. 3. From underneath the instrument panel, disengage the connector lock and disconnect the instrument panel wire harness connector (1) from the blower motor (2). 4. Remove the three screws (3) that secure the blower motor and the wire lead bracket (4) (if equipped) to the bottom of the HVAC housing (5) and remove the blower motor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal > Page 5752 Blower Motor: Service and Repair Installation INSTALLATION NOTE: LHD model shown. RHD model similar. 1. Position the blower motor (2) into the bottom of the HVAC housing (5). 2. Install the three screws (3) that secure the blower motor and the wire lead bracket (4) (if equipped) to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the instrument panel wire harness connector (1) to the blower motor and engage the connector lock. 4. If equipped, install the silencer below the passenger side of the instrument panel. 5. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5756 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 5757 Blower Motor Resistor: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY RESISTOR-BLOWER MOTOR - (INSTRUMENT PANEL) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Description Blower Motor Resistor: Description and Operation Description DESCRIPTION The blower motor resistor is mounted to the HVAC housing on the passenger side of the vehicle. The blower motor resistor consists of a molded plastic mounting plate (1) with an integral wire connector receptacle (2). Concealed behind the mounting plate are resistors (3) located between a two-piece stamped steel base (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Description > Page 5760 Blower Motor Resistor: Description and Operation Operation OPERATION The blower motor resistor is connected to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The blower motor resistor has three resistors, each of which will reduce the current flow through the blower motor to change the blower motor speed. The blower motor control for the heating-A/C system directs the ground path for the blower motor through the correct resistor to obtain the selected speed. With the blower motor control in the lowest speed position, the ground path for the blower motor is applied through all of the resistors. Each higher speed selected with the blower motor control applies the blower motor ground path through fewer of the resistors, increasing the blower motor speed. When the blower motor control is in the highest speed position, the blower motor resistor is bypassed and the blower motor receives a direct path to ground. The blower motor resistor cannot be adjusted or repaired and it must be replaced if found inoperative or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Page 5761 Blower Motor Resistor: Testing and Inspection BLOWER MOTOR RESISTOR WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: See Wiring Information for circuit descriptions and diagrams, Wiring Information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector from the blower motor resistor See: Service and Repair/Removal. 3. Using an ohmmeter, check for continuity between all of the blower motor resistor terminals. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor speed control and the blower motor resistor or blower motor as required. If not OK, replace the inoperative blower motor resistor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Removal Blower Motor Resistor: Service and Repair Removal REMOVAL WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the blower motor resistors to cool before performing diagnosis or service. Failure to follow these instructions may result in possible serious injury. CAUTION: Do not operate the blower motor with the blower motor resistor removed from the circuit. Failure to follow these instructions may result in vehicle damage. NOTE: LHD model shown. RHD model similar. 1. Disconnect and isolate the negative battery cable. 2. If equipped, remove the two push-pins and silencer panel from the passenger side of the instrument panel. 3. Disconnect the wire harness connector (1) from the blower motor resistor (2). 4. Remove the two screws (4) that secure the blower motor resistor to the HVAC housing (3) and remove the resistor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Removal > Page 5764 Blower Motor Resistor: Service and Repair Installation INSTALLATION NOTE: LHD model shown. RHD model similar. 1. Position the blower motor resistor (2) onto the bottom of the HVAC housing (3). 2. Install the two screws (4) that secure the blower motor resistor to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. Connect the wire harness connector (1) to the blower motor resistor. 4. If equipped, install the silencer panel and two push-pins. 5. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Description and Operation Cabin Air Filter: Description and Operation DESCRIPTION Some models are equipped with a particulate air filter (1) that helps purify the outside air entering the HVAC housing. The filter is mounted in the passenger compartment, behind the glove box bin. The filter should be replaced at least once a year or every 24,000 km (15,000 miles) and checked if heating-A/C system performance seems lower than expected. The particulate air filter is labeled with an arrow (2) to indicate the direction of air flow through the filter. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair > Procedures Cabin Air Filter: Procedures REMOVAL NOTE:LHD model shown in illustrations. RHD model similar. NOTE:Illustration shown with instrument panel removed for clarity. 1. Remove the glove box bin. 2. Disengage the two retaining tabs (1) that secure the particulate air filter cover (2) to the passenger side of the HVAC housing (3) and remove the cover. 3. Remove the particulate air filter (1) from the HVAC housing (2) by pulling the filter element straight out of the housing. INSTALL NOTE:The particulate air filter is labeled with an arrow to indicate air flow direction through the filter. Make sure to properly install the particulate air filter. Failure to properly install the filter will result in the need to replace the filter sooner than required by design. NOTE:LHD model shown in illustrations. RHD model similar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 5770 1. Install the particulate air filter (1) into the filter opening in the HVAC housing (2). Insert the particulate air filter directly into the housing with the arrow on the filter pointing to the floor. 2. Position the particulate air filter cover (2) to the HVAC housing (3) and engage the two retaining tabs (1) that secure the cover to the housing. Make sure the retaining tabs are fully engaged. 3. Install the glove box bin Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 5771 Cabin Air Filter: Removal and Replacement Particulate Air Filter - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: Always make sure the A/C-heater system is turned off and that the ignition switch is in the OFF position prior to servicing the particulate air filter. Never place fingers or other objects into the filter opening of the HVAC housing. Failure to follow this warning may result in serious injury. NOTE: LHD model shown in illustrations. RHD model similar. NOTE: Illustration shown with instrument panel removed for clarity. 1. Remove the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Removal. 2. Disengage the two retaining tabs (1) that secure the particulate air filter cover (2) to the passenger side of the HVAC housing (3) and remove the cover. 3. Remove the particulate air filter (1) from the HVAC housing (2) by pulling the filter element straight out of the housing. Particulate Air Filter - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair > Procedures > Page 5772 INSTALLATION NOTE: The particulate air filter is labeled with an arrow to indicate air flow direction through the filter. Make sure to properly install the particulate air filter. Failure to properly install the filter will result in the need to replace the filter sooner than required by design. NOTE: LHD model shown in illustrations. RHD model similar. 1. Install the particulate air filter (1) into the filter opening in the HVAC housing (2). Insert the particulate air filter directly into the housing with the arrow on the filter pointing to the floor. 2. Position the particulate air filter cover (2) to the HVAC housing (3) and engage the two retaining tabs (1) that secure the cover to the housing. Make sure the retaining tabs are fully engaged. 3. Install the glove box bin See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Control Valve Assembly > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Control Valve Assembly > Component Information > Locations > Page 5777 Compressor Control Valve Assembly: Diagrams Connector - (POWERTRAIN) 2 WAY SOLENOID-A/C COMPRESSOR - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Description and Operation > A/C Compressor Hub and Pulley - Description Compressor Pulley: Description and Operation A/C Compressor Hub and Pulley - Description HUB AND PULLEY NOTE: Typical clutchless A/C compressor pulley and drive hub shown. The non-serviceable A/C compressor hub and pulley assembly provides the means to drive the A/C compressor using the engine accessory drive belt. The hub and pulley assembly consists of an aluminum drive hub (1) with composite tabs (2) that are positioned between rubber dampeners (3), which are located inside of a composite pulley (4). The A/C pulley has a bearing (5) which is retained to the nose of the A/C compressor with a snap ring (6). The drive hub and shim (7) are retained to the compressor shaft by use of left handed threads. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Description and Operation > A/C Compressor Hub and Pulley - Description > Page 5782 Compressor Pulley: Description and Operation A/C Compressor Hub and Pulley - Operation HUB AND PULLEY NOTE: Typical clutchless compressor pulley drive hub shown. This compressor design does not require the use of an electromagnetic clutch, as the A/C compressor is controlled by an integral control valve that allows refrigerant to bypass within the compressor See: Description and Operation/A/C Compressor - Description. The three bridges (1) located on compressor drive hub (2) are designed to break away in the event of compressor seizure. This action prevents damage to the serpentine accessory drive belt See: Service and Repair. NOTE: The compressor drive hub and the pulley and bearing assembly can not be serviced separately from the A/C compressor. In the event of drive hub or pulley and bearing assembly damage or failure, the A/C compressor, drive hub and pulley and bearing must be replaced as an assembly. The compressor drive hub and the pulley and bearing assembly can not be serviced separately from the A/C compressor. The A/C compressor must be replaced if the drive hub or pulley and bearing assembly is found to be worn or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Description and Operation > Page 5783 Compressor Pulley: Service and Repair HUB AND PULLEY INSPECTION NOTE: The compressor drive hub and the pulley and bearing assembly can not be serviced separately from the A/C compressor. In the event of drive hub or pulley and bearing assembly damage or failure, the A/C compressor, drive hub and pulley and bearing must be replaced as an assembly. NOTE: Typical clutchless compressor drive hub and pulley and bearing assembly shown. The bridges (1) located on the non-serviceable compressor hub (2) are designed to break away in the event of compressor seizure. Examine the bridges for separation or cracks (3). Damage to the bridges are an indication of excessive compressor torque, which is most likely caused by compressor failure. Check the non-serviceable pulley bearing (4) for roughness or excessive noise. Check the pulley dampeners (5) for excessive play which can be caused by deterioration or damage. Inspect the belt surfaces of the non-serviceable pulley (4) for wear. If the pulley surfaces are oily, inspect the shaft and nose area of the A/C compressor for refrigerant oil. If refrigerant oil is found, the compressor shaft seal is leaking and the A/C compressor must be replaced. Replace the A/C compressor if wear or damage is found to the drive hub or pulley and bearing assembly See: Service and Repair/A/C Compressor - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > A/C Condenser - Description Condenser HVAC: Description and Operation A/C Condenser - Description DESCRIPTION NOTE: A/C condenser with automatic transmission cooler shown. A/C Condenser without cooler similar. The A/C condenser (1) is located in the front of the engine compartment behind the grille. The A/C condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the A/C compressor to give up its heat to the air passing over the condenser fins, which causes the refrigerant to cool and change to a liquid state. The A/C condenser is equipped with tapping blocks for the A/C discharge line and the A/C liquid line (2) and an integral automatic transmission cooler (3), when equipped with an automatic transaxle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > A/C Condenser - Description > Page 5788 Condenser HVAC: Description and Operation A/C Condenser - Operation OPERATION When air passes through the fins of the A/C condenser, the high-pressure refrigerant gas within the A/C condenser gives up its heat. The refrigerant then condenses as it leaves the A/C condenser and becomes a high-pressure liquid. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the A/C system. Therefore, it is important that there are no objects placed in front of the radiator grille openings at the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or A/C condenser service. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C condenser has no serviceable parts. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever a refrigerant line is disconnected from the A/C condenser. The A/C condenser cannot be repaired and must be replaced if leaking or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > A/C Condenser - Removal Condenser HVAC: Service and Repair A/C Condenser - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. CAUTION: Before removing the A/C condenser, note the location of each of the radiator/condenser air seals. These air seals are used to direct air through the A/C condenser and radiator. The air seals must be reinstalled in their proper locations in order for the A/C and engine cooling systems to perform as designed. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. If equipped with the 2.0L diesel engine, remove the front fascia See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Removal. NOTE: It is not necessary to remove the hood latch from the upper radiator support on gasoline engine equipped models for A/C condenser service. 4. If equipped with 2.4L turbo engine, remove the charge air cooler to throttle body hose . 5. If equipped with a gasoline engine, remove the upper radiator support and position it out of the way See: Body and Frame/Spoilers, Flaps, and Air Dams/Air Dam/Service and Repair/Upper Closure Panel - Removal. 6. If equipped with 2.4L turbo engine, remove the charge air cooler . 7. On gasoline engine equipped models, carefully push the radiator (1) slightly rearward to gain access to the A/C condenser (2). 8. Remove the nut (3) that secures the A/C discharge line (4) to the right side of the A/C condenser and remove and discard the O-ring seal and gasket. 9. Install plugs in, or tape over the opened discharge line fitting and the condenser inlet port. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > A/C Condenser - Removal > Page 5791 NOTE: Illustration shown with front fascia removed for clarity. 10. Raise and support the vehicle. NOTE: On gasoline engine equipped models, reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle to gain access to the A/C liquid line. 11. Remove the nut (1) that secures the A/C liquid line (2) to the right side of the A/C condenser (3). 12. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket. 13. Install plugs in, or tape over the opened liquid line fitting and the condenser outlet port. NOTE: Illustration shown with front fascia and diesel engine charge air cooler (CAC) (when equipped) removed for clarity. 14. Remove the two bolts (3) that secure the lower condenser brackets to the radiator (5). 15. Lower the vehicle. 16. If equipped, disconnect the automatic transmission cooler lines (2) from the left side of the A/C condenser (1) See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Fluid Line/Hose/Service and Repair. 17. If equipped with the 2.0L diesel engine, remove the charge air cooler (CAC) . 18. Carefully lift the A/C condenser straight up and disengage the two upper condenser brackets (4) from the radiator and remove the condenser from the engine compartment. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > A/C Condenser - Removal > Page 5792 Condenser HVAC: Service and Repair A/C Condenser - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Service and Repair/Refrigerant Oil Level . NOTE: If only the A/C condenser is being replaced, add 20 milliliters (0.7 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: Illustration shown with front fascia and diesel engine charge air cooler (CAC) (when equipped) removed for clarity. 1. Carefully lower the A/C condenser (1) straight down in front of the radiator (5) and engage the upper condenser brackets (4) to the radiator. 2. If equipped with the 2.0L diesel engine, install the charge air cooler (CAC). . 3. If equipped, connect the automatic transmission cooler lines (2) to the left side of the A/C condenser See: Transmission and Drivetrain/Continuously Variable Transmission/Transaxle/Fluid Line/Hose/Service and Repair. 4. Raise and support the vehicle. 5. Install the two bolts (3) that secure the lower condenser brackets to the radiator. Tighten the bolts to 4.5 Nm (40 in. lbs.). NOTE: Illustration shown with front fascia removed for clarity. NOTE: On gasoline engine equipped models, reach up through the opening in the bottom of the front fascia located in the right front corner Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > A/C Condenser - Removal > Page 5793 of the vehicle to gain access to the A/C liquid line. 6. Remove the tape or plug from the liquid line fitting and the condenser outlet port. 7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the A/C liquid line (2) to the A/C condenser (3) and install the retaining nut (1). Tighten the nut to 5 Nm (44 in. lbs.). 9. Lower the vehicle. 10. Remove the tape or plug from the discharge line fitting and the condenser inlet port. 11. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 12. On gasoline engine equipped models, carefully push the radiator (1) slightly rearward to gain access to the A/C condenser (2). 13. Connect the A/C discharge line (4) to the A/C condenser and install the retaining nut (3). Tighten the nut to 5 Nm (44 in. lbs.). 14. If equipped with 2.4L turbo engine, install the charge air cooler . 15. If equipped with a gasoline engine, reposition and install the upper radiator support See: Body and Frame/Spoilers, Flaps, and Air Dams/Air Dam/Service and Repair/Upper Closure Panel - Installation. 16. If equipped with 2.4L turbo engine, install the charge air cooler to throttle body hose . 17. If equipped with the 2.0L diesel engine, install the front fascia See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Installation. 18. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 19. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate 20. If the A/C condenser is being replaced, add 20 milliliters (0.7 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Service and Repair/Refrigerant Oil Level. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 21. Charge the A/C system See: Service and Repair/Refrigerant System Charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > A/C Heater Control C1 (Instrument Panel) 12 Way Control Assembly: Diagrams A/C Heater Control C1 (Instrument Panel) 12 Way Connector C1 - (INSTRUMENT PANEL) 12 WAY CONTROL-A/C-HEATER - (INSTRUMENT PANEL) 12 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > A/C Heater Control C1 (Instrument Panel) 12 Way > Page 5799 Control Assembly: Diagrams A/C Heater Control C2 (Instrument Panel) 5 Way Connector C2 - (INSTRUMENT PANEL) 5 WAY CONTROL-A/C-HEATER - (INSTRUMENT PANEL) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 5800 Control Assembly: Description and Operation DESCRIPTION NOTE: Typical A/C-heater control shown. The A/C-heater control (1) for the manual temperature control (MTC) single zone system allows one temperature setting for the entire vehicle. All controls are identified by ISO graphic symbols. The heating-A/C system uses a combination of electrical and cable operated controls. These controls provide the vehicle operator with a number of setting options to help control the climate and comfort within the vehicle. The A/C-heater control is located in the instrument panel and contains: - a rotary control for mode control of the discharged air (2). - a rotary control for blower motor speed selection and to turn the blower motor off (3). - a rotary control for temperature control of the discharged air (4). - a push-button control to turn the rear window defogger system on and off (5). - a push-button control for recirculation control of the discharged air (6). - a push-button control to turn the A/C system on and off (7). The A/C-heater control cannot be repaired or adjusted and it must be replaced if found inoperative or damaged. The control knobs for the A/C-heater control are available for service replacement. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C and Heater Control - Removal Control Assembly: Service and Repair A/C and Heater Control - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Typical A/C-heater control and center bezel shown. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel (7) from the instrument panel and disconnect the wiring connector for the clock, power window switches and the accessory switches, as equipped See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. NOTE: To aid in reinstallation, note the installed positions of the control cables prior to removal. 3. Using a small screwdriver or similar tool, disengage the retaining clips that secure the control cables (1 and 9) to the back of the A/C-heater control (8). 4. Using a small screwdriver or similar tool, disengage the retaining clips that secure the control cables to the mode control sector gear (2) and the temperature control sector gear (5). 5. Disconnect the wire harness connectors (3 and 4) from the rear of the A/C-heater control and place the center bezel on a work bench. 6. Remove the four screws (6) that secure the A/C-heater control to the back of the center bezel and remove the control. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C and Heater Control - Removal > Page 5803 Control Assembly: Service and Repair A/C and Heater Control - Installation INSTALLATION NOTE: Typical A/C-heater control and center bezel shown. 1. Install the A/C-heater control (8) into the instrument panel center bezel (7). 2. Install the four screws (6) that secure the A/C-heater control to the center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Position the center bezel to the instrument panel and connect the wire harness connectors (3 and 4) to the back of the A/C-heater control. NOTE: Install the mode control cable onto the A/C heater control first. Then install the temperature control cable. 4. Connect the control cables (1 and 9) to the mode door control sector gear (2) and the temperature control sector gear (5) and fully engage the retaining clips. Make sure the retaining clips are fully engaged to the sector gears. 5. Connect the control cables to the back of the A/C-heater control and fully engage the retaining clips. Make sure the retaining clips are fully engaged to the back of the A/C-heater control. 6. Connect the wire harness connectors to the accessory switches, power window switches and clock, as equipped and install the center bezel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 7. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Description Evaporator Core: Description and Operation Description DESCRIPTION NOTE: LHD model shown. RHD model similar. The A/C evaporator (1) for the heating-A/C system is mounted in the HVAC housing, which is located behind the instrument panel. The A/C evaporator and its insulator (2) are positioned within the HVAC housing so that all air entering the housing must pass over the evaporator fins before it is distributed through the heating-A/C system ducts and outlets. A tapping block (3) and O-ring seals are used to connect and seal the A/C evaporator tubes (4) to the underhood refrigerant lines. The A/C evaporator can only be serviced by removing and disassembling the HVAC housing assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Description > Page 5808 Evaporator Core: Description and Operation Operation OPERATION Refrigerant enters the A/C evaporator through the A/C orifice tube as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the A/C evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the A/C evaporator. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C evaporator has no serviceable parts except for the O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The A/C evaporator cannot be repaired and must be replaced if leaking or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Removal Evaporator Core: Service and Repair Removal REMOVAL NOTE: The HVAC housing assembly must be removed from vehicle and disassembled for service of the A/C evaporator. NOTE: LHD model shown. RHD model similar. 1. Remove the HVAC housing and place it on a workbench See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/HVAC Housing - Removal. 2. Disassemble the HVAC housing to gain access to the A/C evaporator See: Housing Assembly HVAC/Service and Repair/Overhaul/Disassembly. NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced. 3. Carefully lift the A/C evaporator (1) and the foam insulator (2) out of the lower half of the HVAC housing (3). NOTE: If the seal around the evaporator tube tapping block is deformed or damaged, the seal must be replaced. 4. If required, remove the seal (4) from around the evaporator tube tapping block (5). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Removal > Page 5811 Evaporator Core: Service and Repair Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Service and Repair/Refrigerant Oil Level . NOTE: If only the A/C evaporator is being replaced, add 20 milliliters (0.7 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown. RHD model similar. 1. If removed, install the seal (4) onto the evaporator tube tapping block (5). NOTE: Make sure that the foam insulator is properly positioned in the HVAC housing. 2. Carefully install the A/C evaporator (1) and foam insulator (2) into the lower half of the HVAC housing (3). 3. Assemble the HVAC housing See: Housing Assembly HVAC/Service and Repair/Overhaul/Assembly. 4. Install the HVAC housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/HVAC Housing - Installation. 5. If the A/C evaporator is being replaced, add 20 milliliters (0.7 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Service and Repair/Refrigerant Oil Level. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Description and Operation Evaporator Drain Tube: Description and Operation DESCRIPTION Condensation that accumulates within the HVAC housing is drained through a port located at the bottom of the HVAC housing (1). A rubber condensation drain tube (2) is installed onto the drain port and protrudes through a rubber grommet (3) in the left side floor panel (4) to ensure that any condensate completely drains out of the HVAC housing and to the ground. NOTE: The condensation drain tube must be kept open to prevent water from collecting in the bottom of the HVAC housing. The drain tube is designed to keep contaminants from entering the HVAC housing. If the tube is pinched or blocked, condensate cannot drain, causing water to back up and spill into the passenger compartment. It is normal to see condensation drainage below the vehicle in warm weather. If the condensation drain tube is damaged or missing, it must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Service and Repair > Condensation Drain Tube - Removal Evaporator Drain Tube: Service and Repair Condensation Drain Tube - Removal REMOVAL 1. Pull back the floor carpet to gain access to the condensation drain tube (2) located on the left side of the vehicle at the front right of the foot well See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Carpet - Removal. 2. Disconnect the condensation drain tube from the bottom of the HVAC housing (1). 3. Remove the condensate drain tube from the rubber grommet (3) in the front floor panel (4). 4. If required, remove the rubber grommet from the floor panel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Service and Repair > Condensation Drain Tube - Removal > Page 5817 Evaporator Drain Tube: Service and Repair Condensation Drain Tube - Installation INSTALLATION 1. If removed, install the rubber grommet (3) onto the driver side front floor panel (4). Make sure the grommet is fully engaged to the floor panel. 2. Connect the condensation drain tube (2) onto the drain port located on the bottom of the HVAC housing (1). 3. Install the condensation drain tube into the rubber grommet. 4. Reinstall the floor carpet See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Carpet - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5821 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5822 Evaporator Temperature Sensor / Switch: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SENSOR-EVAPORATOR TEMPERATURE - (INSTRUMENT PANEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Evaporator Temperature Sensor - Description Evaporator Temperature Sensor / Switch: Description and Operation Evaporator Temperature Sensor - Description DESCRIPTION The evaporator temperature sensor measures the temperature of the conditioned air downstream of the A/C evaporator. The evaporator temperature sensor is an electrical thermistor (1) mounted on the end of a molded plastic housing (2) that is inserted into the driver side of the HVAC housing near the coldest point of the A/C evaporator. The evaporator temperature sensor is retained in the HVAC housing by two integral retaining tabs (3) and is connected to the vehicle electrical system by use of a wire lead and connector (4) with two terminals. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Evaporator Temperature Sensor - Description > Page 5825 Evaporator Temperature Sensor / Switch: Description and Operation Evaporator Temperature Sensor - Operation OPERATION The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an input signal to the Cabin Compartment Node (CCN). The CCN uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the CCN through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The CCN uses the monitored voltage reading as an indication of evaporator temperature. The CCN is programmed to respond to this input by requesting the Powertrain Control Module (PCM) or the Engine Control Module (ECM) (depending on engine application) to cycle the A/C clutch off and on as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing See: Compressor HVAC/Description and Operation/A/C Compressor - Operation. The evaporator temperature sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The evaporator temperature sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Evaporator Temperature Sensor - Removal Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Illustration shown with air distribution housing removed for clarity. NOTE: It is not necessary to remove and disassemble the HVAC housing to service the evaporator temperature sensor. The evaporator temperature sensor can be removed for service from underneath the instrument panel. 1. Disconnect and isolate the negative battery cable. 2. Reach up under the driver side of the instrument panel and disconnect the electrical connector for the evaporator temperature sensor (1) from the instrument panel wire harness. 3. Using needle nose pliers, disengage the two retaining tabs (3) that secure the evaporator temperature sensor to the HVAC housing (2) by carefully pulling the sensor straight out of the side of the HVAC housing. 4. Route the electrical connector and wire lead of the evaporator temperature sensor out from under the heater core tubes and remove the sensor from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Evaporator Temperature Sensor - Removal > Page 5828 Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Installation INSTALLATION NOTE: Illustration shown with air distribution housing removed for clarity. 1. Route the electrical connector and wire lead of the evaporator temperature sensor (1) under the heater core tubes located on the driver side of the HVAC housing (2). 2. Install the evaporator temperature sensor into the driver side of the HVAC housing. Make sure the retaining tabs (3) are fully engaged to the housing. 3. Connect the electrical connector for the evaporator temperature sensor to the instrument panel wire harness. 4. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > A/C Orifice Tube - Description Expansion Block/Orifice Tube: Description and Operation A/C Orifice Tube - Description DESCRIPTION The A/C orifice tube establishes the pressure differential between the high and low pressure sides of the A/C system by providing a restriction between the A/C condenser and the A/C evaporator. The A/C orifice tube in this vehicle is installed in the A/C liquid line and is of a variable orifice valve (VOV) design. The variable A/C orifice tube consists of the inlet filter screen (5), the bi-metal coil (4), the fixed port (3), the variable port (6), metering orifices (1), a nylon mesh diffuser screen (7) and two rubber O-rings (2) which seal the tube to the inside of the A/C liquid line to prevent refrigerant from bypassing the metering orifices. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > A/C Orifice Tube - Description > Page 5833 Expansion Block/Orifice Tube: Description and Operation A/C Orifice Tube - Operation OPERATION The variable A/C orifice tube provides improved A/C system cooling during city driving and when under heavy loads by controlling refrigerant flow through the two parallel flow paths integral to the orifice tube. Under normal loads, the refrigerant flows through the inlet filter screen, the fixed and variable ports and both metering orifices. As the load on the A/C system increases, the temperature of the refrigerant leaving the A/C condenser increases, which causes the bi-metal coil to expand and restrict the flow of refrigerant through the variable port of the tube. Restricting the flow of refrigerant through the variable port and its orifice provides a greater pressure differential between the high and low pressure sides of the A/C system, resulting in colder refrigerant vapor traveling through the A/C evaporator to help remove the heat from the conditioned air flowing into the passenger compartment. The A/C orifice tube is not serviceable and the A/C liquid line must be replaced if the orifice tube is found inoperative See: Hose/Line HVAC/Description and Operation/A/C Liquid Line - Description. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Description Heater Core: Description and Operation Description DESCRIPTION NOTE: LHD model shown. RHD model similar. The heater core (1) for the heating-A/C system is mounted within the HVAC air distribution housing, which is located behind the instrument panel. The heater core is a heat exchanger made of rows of tubes with fins and is positioned within the air distribution housing so that only the selected amount of air entering the housing passes through the heater core before it is distributed through the heating-A/C system ducts and outlets. One end of the heater core is fitted with a tank (2) that includes the fittings for the heater core tubes (3). The heater core can only be serviced by removing the HVAC housing from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Description > Page 5838 Heater Core: Description and Operation Operation OPERATION Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and it must be replaced if inoperative, leaking or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Installation Heater Core: Service and Repair Installation INSTALLATION NOTE: LHD model with A/C shown. RHD and heater-only models similar. 1. Carefully install the heater core (6) into the left side of the air distribution housing (5). 2. On RHD models, install the air distribution housing (5) onto the HVAC housing (9) See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/HVAC Housing - Installation. 3. Install the retaining bracket (4) and screw (3) that secure the heater core tubes (8). Tighten the screw to 1.2 Nm (10 in. lbs.) 4. Install the flange (2) that secures the heater core tubes to the front of the HVAC housing. 5. Install the screw (10) that secures the flange to the HVAC housing. Tighten the screw to 1.2 Nm (10 in. lbs.). NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 6. Install the foam seal (1) onto the flange. 7. Install the left side front floor duct See: Air Duct/Service and Repair/Floor Distribution Duct - Installation. NOTE: If the heater core is being replaced, flush the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair . 8. Install the HVAC housing assembly See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/HVAC Housing - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Installation > Page 5841 Heater Core: Service and Repair Removal REMOVAL NOTE: The HVAC housing assembly must be removed from vehicle for service of the heater core. NOTE: LHD model with A/C shown. RHD and heater-only models similar. 1. Remove the HVAC housing assembly and place it on a workbench See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/HVAC Housing - Removal. 2. Remove the left side front floor duct See: Air Duct/Service and Repair/Floor Distribution Duct Removal. NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 3. Remove the foam seal (1) from the flange (2) located on the front of the HVAC housing (9). 4. Remove the screw (10) that secures the flange to the front of the HVAC housing and remove the flange. 5. Remove the screw (3) that secures the retaining bracket (4) for the heater core tubes (8) to the left side of the air distribution housing (5). 6. On RHD models, remove the air distribution housing from the HVAC housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/HVAC Housing - Removal 7. Carefully pull the heater core (6) out of the driver side of the air distribution housing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > High Pressure Relief Valve - Operation High Pressure Safety Valve HVAC: Description and Operation High Pressure Relief Valve Operation HIGH PRESSURE RELIEF VALVE The high pressure relief valve vents refrigerant from the A/C system when a discharge pressure of 3445 to 4135 kPa (500 to 600 psi) or above is reached. The high pressure relief valve closes with a minimum discharge pressure of 2756 kPa (400 psi) is reached. The high pressure relief valve should not open when the A/C system is operating correctly. If the high pressure relief valve vents refrigerant, there is most likely a problem within the A/C refrigerant system. The high pressure relief valve vents only enough refrigerant to reduce the A/C system pressure, and then re-seats itself. If the high pressure relief valve vents refrigerant, see the A/C System Diagnosis chart See: Testing and Inspection. The high pressure relief valve is factory-calibrated and cannot be adjusted or repaired, and must not be removed or otherwise disturbed. The valve is only serviced as a part of the A/C compressor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description Hose/Line HVAC: Description and Operation A/C Discharge Line - Description DESCRIPTION NOTE: Typical A/C discharge line shown. The A/C discharge line (1) is the refrigerant line that carries refrigerant from the A/C compressor to the A/C condenser and includes the high side service port (2) and a fitting (3) for the A/C pressure transducer (4). CAUTION: If replacing the A/C discharge line, be sure to use the discharge line designed for the A/C compressor in the vehicle. If replacing the 6SEU16 compressor, be sure to use the latest level of A/C discharge line during replacement. Failure to use the correct A/C discharge line could result in possible discharge line and/or compressor damage. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C discharge line has no serviceable parts except for the metal gaskets (5) and rubber O-ring seals (6) and the high side service port valve core. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C discharge line is disconnected. The A/C discharge line cannot be repaired and must be replaced if leaking or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 5850 Hose/Line HVAC: Description and Operation A/C Liquid Line - Description DESCRIPTION The A/C liquid line (1) is the refrigerant line that carries refrigerant from the A/C condenser to the A/C evaporator. The A/C liquid line contains the low side service port (2) and the variable A/C orifice tube. The A/C liquid line is only serviced as an assembly with the upper A/C suction line (3). NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C liquid/suction line assembly has no serviceable parts except for the metal gaskets (4), rubber O-ring seals (5) and the low side service port valve core. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C liquid/suction line assembly is removed. The A/C liquid/suction line assembly cannot be repaired and must be replaced if found to be leaking or damaged, or if an internal failure of the A/C compressor has occurred. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 5851 Hose/Line HVAC: Description and Operation A/C Suction Line - Description DESCRIPTION The A/C suction line is serviced in two sections. The upper section of the A/C suction line (1) is the refrigerant line that carries refrigerant from the A/C evaporator to the A/C accumulator. The lower section of the A/C suction line (2) carries refrigerant from the A/C accumulator to the A/C compressor. The upper portion of the A/C suction line is only serviced as an assembly with the A/C liquid line (5). NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The lower A/C suction line and the A/C liquid/suction line assembly has no serviceable parts except for the rubber O-ring seals (3), metal gaskets (4) and the low side service port valve core. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the lower A/C suction line and/or the A/C liquid/suction line assembly is disconnected. The lower A/C suction line and the A/C liquid/suction line assembly cannot be repaired and must be replaced leaking or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal Hose/Line HVAC: Service and Repair A/C Discharge Line - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. CAUTION: If replacing the A/C discharge line, be sure to use the discharge line designed for the A/C compressor in the vehicle. If replacing the 6SEU16 compressor, be sure to use the latest level of A/C discharge line during replacement. Failure to use the correct A/C discharge line could result in possible discharge line and/or compressor damage. NOTE: It is not necessary to completely remove the front fascia for A/C discharge line service. NOTE: 5SE12 A/C compressor shown. 6SEU16 compressor similar. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Remove the splash shield from the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 5. Remove the nut (1) that secures the A/C discharge line (2) to the A/C compressor (3). 6. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened discharge line fitting and the compressor port. 8. Lower the vehicle. 9. Remove the upper radiator closure panel and carefully pull the top of the fascia forward to gain access to the A/C discharge line (3) See: Body and Frame/Spoilers, Flaps, and Air Dams/Air Dam/Service and Repair/Upper Closure Panel - Removal. 10. Reach down through the opening between the radiator and the front fascia and disconnect the wire harness connector (1) from the A/C pressure transducer (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5854 11. Remove the nut (5) that secures the A/C discharge line to the right side of the A/C condenser (4). 12. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket. 13. Install plugs in, or tape over the discharge line fitting and the condenser port. 14. If necessary, remove the A/C pressure transducer from the A/C discharge line. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5855 Hose/Line HVAC: Service and Repair A/C Discharge Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: If replacing the A/C discharge line, be sure to use the discharge line designed for the A/C compressor in the vehicle. If replacing the 6SEU16 compressor, be sure to use the latest level of A/C discharge line during replacement. Failure to use the correct A/C discharge line could result in possible discharge line and/or compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. 1. If removed, install the A/C pressure transducer (2) onto the A/C discharge line (3). Tighten the A/C pressure transducer securely. 2. Position the A/C discharge line into the engine compartment. 3. Remove the tape or plugs from the discharge line fitting and the condenser port. 4. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Reach down through the opening between the radiator and the front fascia and connect the A/C discharge line to the A/C condenser (4). 6. Install the nut (5) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 5 Nm (44 in. lbs.). 7. Connect the wire harness connector (1) to the A/C pressure transducer. 8. Install the upper radiator closure panel See: Body and Frame/Spoilers, Flaps, and Air Dams/Air Dam/Service and Repair/Upper Closure Panel Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5856 NOTE: 5SE12 A/C compressor shown. 6SEU16 compressor similar. 9. Raise and support the vehicle. 10. Remove the tape or plugs from the discharge line fitting and the compressor port. 11. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 12. Connect the A/C discharge line (2) to the A/C compressor (3). 13. Install the nut (1) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.). 14. Install the splash shield onto the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 15. Lower the vehicle. 16. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 17. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 18. Adjust the refrigerant oil level See: Service and Repair/Refrigerant Oil Level. 19. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5857 Hose/Line HVAC: Service and Repair A/C Liquid Line - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The A/C liquid line is only serviced as an assembly with the upper A/C suction line. NOTE: LHD model shown in illustrations. RHD model similar. NOTE: Illustration shown with front fascia removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Remove the A/C accumulator See: Accumulator HVAC/Service and Repair/Accumulator Removal. 5. Reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle and remove the nut (3) that secures the A/C liquid line (1) to the A/C condenser (2). 6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and accumulator ports. 8. Lower the vehicle. 9. Remove the three nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the engine compartment and remove the heat shield. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5858 NOTE: It is only necessary to position the windshield washer reservoir, power steering fluid reservoir and engine coolant reservoir out of the way. Draining of the washer fluid, power steering fluid and engine coolant is not required. 10. Remove the windshield washer reservoir, power steering reservoir and the engine coolant reservoir and position them out of the way. 11. Remove the nut (1) that secures the refrigerant line retaining bracket (2) to the right front strut tower (5). 12. On RHD models, disengage the retainers that secure the power brake booster vacuum supply hose to the dash panel and position the vacuum line out of the way. 13. Remove the bolt (3) that secures the A/C liquid and suction line assembly (4) to the A/C evaporator (6). 14. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals. 15. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports. 16. Remove the A/C liquid and suction line assembly from the engine compartment. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5859 Hose/Line HVAC: Service and Repair A/C Liquid Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: The A/C liquid line must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C liquid line can prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown in illustrations. RHD model similar. 1. Position the A/C liquid and suction line assembly (4) into the engine compartment. 2. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports. 3. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the A/C liquid and suction line assembly to the A/C evaporator (6). 5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 12 Nm (105 in. lbs.). 6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose to the dash panel. 7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5). Tighten the nut to 4.5 Nm (40 in. lbs.). 8. Install the windshield washer reservoir, power steering fluid reservoir and the engine coolant reservoir. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5860 9. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment. 10. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 Nm (10 in. lbs.). NOTE: Illustration shown with front fascia removed for clarity. 11. Raise and support the vehicle. 12. Remove the tape or plugs from the liquid line fitting and the condenser port. 13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 14. Reach up through the opening in the bottom of the front fascia and connect the A/C liquid line (1) to the A/C condenser (2) and install the retaining nut (3). Tighten the nut to 5 Nm (44 in. lbs.). 15. Install the A/C accumulator See: Accumulator HVAC/Service and Repair/Accumulator Installation. 16. Lower the vehicle. 17. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 18. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate 19. Adjust the refrigerant oil level See: Service and Repair/Refrigerant Oil Level. 20. Charge the A/C system See: Service and Repair/Refrigerant System Charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5861 Hose/Line HVAC: Service and Repair A/C Discharge Line - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. CAUTION: If replacing the A/C discharge line, be sure to use the discharge line designed for the A/C compressor in the vehicle. If replacing the 6SEU16 compressor, be sure to use the latest level of A/C discharge line during replacement. Failure to use the correct A/C discharge line could result in possible discharge line and/or compressor damage. NOTE: It is not necessary to completely remove the front fascia for A/C discharge line service. NOTE: 5SE12 A/C compressor shown. 6SEU16 compressor similar. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Remove the splash shield from the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal. 5. Remove the nut (1) that secures the A/C discharge line (2) to the A/C compressor (3). 6. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened discharge line fitting and the compressor port. 8. Lower the vehicle. 9. Remove the upper radiator closure panel and carefully pull the top of the fascia forward to gain access to the A/C discharge line (3) See: Body and Frame/Spoilers, Flaps, and Air Dams/Air Dam/Service and Repair/Upper Closure Panel - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5862 10. Reach down through the opening between the radiator and the front fascia and disconnect the wire harness connector (1) from the A/C pressure transducer (2). 11. Remove the nut (5) that secures the A/C discharge line to the right side of the A/C condenser (4). 12. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket. 13. Install plugs in, or tape over the discharge line fitting and the condenser port. 14. If necessary, remove the A/C pressure transducer from the A/C discharge line. A/C Discharge Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: If replacing the A/C discharge line, be sure to use the discharge line designed for the A/C compressor in the vehicle. If replacing the 6SEU16 compressor, be sure to use the latest level of A/C discharge line during replacement. Failure to use the correct A/C discharge line could result in possible discharge line and/or compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. 1. If removed, install the A/C pressure transducer (2) onto the A/C discharge line (3). Tighten the A/C pressure transducer securely. 2. Position the A/C discharge line into the engine compartment. 3. Remove the tape or plugs from the discharge line fitting and the condenser port. 4. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Reach down through the opening between the radiator and the front fascia and connect the A/C discharge line to the A/C condenser (4). 6. Install the nut (5) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 5 Nm (44 in. lbs.). 7. Connect the wire harness connector (1) to the A/C pressure transducer. 8. Install the upper radiator closure panel See: Body and Frame/Spoilers, Flaps, and Air Dams/Air Dam/Service and Repair/Upper Closure Panel Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5863 NOTE: 5SE12 A/C compressor shown. 6SEU16 compressor similar. 9. Raise and support the vehicle. 10. Remove the tape or plugs from the discharge line fitting and the compressor port. 11. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 12. Connect the A/C discharge line (2) to the A/C compressor (3). 13. Install the nut (1) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.). 14. Install the splash shield onto the right side frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 15. Lower the vehicle. 16. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 17. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 18. Adjust the refrigerant oil level See: Service and Repair/Refrigerant Oil Level. 19. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. A/C Liquid Line - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The A/C liquid line is only serviced as an assembly with the upper A/C suction line. NOTE: LHD model shown in illustrations. RHD model similar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5864 NOTE: Illustration shown with front fascia removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Remove the A/C accumulator See: Accumulator HVAC/Service and Repair/Accumulator Removal. 5. Reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle and remove the nut (3) that secures the A/C liquid line (1) to the A/C condenser (2). 6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and accumulator ports. 8. Lower the vehicle. 9. Remove the three nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the engine compartment and remove the heat shield. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5865 NOTE: It is only necessary to position the windshield washer reservoir, power steering fluid reservoir and engine coolant reservoir out of the way. Draining of the washer fluid, power steering fluid and engine coolant is not required. 10. Remove the windshield washer reservoir, power steering reservoir and the engine coolant reservoir and position them out of the way. 11. Remove the nut (1) that secures the refrigerant line retaining bracket (2) to the right front strut tower (5). 12. On RHD models, disengage the retainers that secure the power brake booster vacuum supply hose to the dash panel and position the vacuum line out of the way. 13. Remove the bolt (3) that secures the A/C liquid and suction line assembly (4) to the A/C evaporator (6). 14. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals. 15. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports. 16. Remove the A/C liquid and suction line assembly from the engine compartment. A/C Liquid Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: The A/C liquid line must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C liquid line can prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown in illustrations. RHD model similar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5866 1. Position the A/C liquid and suction line assembly (4) into the engine compartment. 2. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports. 3. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the A/C liquid and suction line assembly to the A/C evaporator (6). 5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 12 Nm (105 in. lbs.). 6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose to the dash panel. 7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5). Tighten the nut to 4.5 Nm (40 in. lbs.). 8. Install the windshield washer reservoir, power steering fluid reservoir and the engine coolant reservoir. 9. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment. 10. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 Nm (10 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5867 NOTE: Illustration shown with front fascia removed for clarity. 11. Raise and support the vehicle. 12. Remove the tape or plugs from the liquid line fitting and the condenser port. 13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 14. Reach up through the opening in the bottom of the front fascia and connect the A/C liquid line (1) to the A/C condenser (2) and install the retaining nut (3). Tighten the nut to 5 Nm (44 in. lbs.). 15. Install the A/C accumulator See: Accumulator HVAC/Service and Repair/Accumulator Installation. 16. Lower the vehicle. 17. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 18. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate 19. Adjust the refrigerant oil level See: Service and Repair/Refrigerant Oil Level. 20. Charge the A/C system See: Service and Repair/Refrigerant System Charge. A/C Suction Line - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The A/C suction line is serviced in two sections. The upper section of the A/C suction line is the refrigerant line that carries refrigerant from the A/C evaporator to the A/C accumulator. The lower section of the A/C suction line carries refrigerant from the A/C accumulator to the A/C compressor. NOTE: LHD model shown in illustrations. RHD model similar. Upper A/C Suction Line NOTE: The upper portion of the A/C suction line is only serviced as an assembly with the A/C liquid line. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5868 NOTE: Illustration shown with front fascia removed for clarity. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Remove the A/C accumulator See: Accumulator HVAC/Service and Repair/Accumulator Removal. 5. Reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle and remove the nut (3) that secures the A/C liquid line (1) to the A/C condenser (2). 6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and accumulator ports. 8. Lower the vehicle. 9. Remove the three nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the engine compartment and remove the heat shield. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5869 NOTE: It is only necessary to position the windshield washer reservoir, power steering fluid reservoir and engine coolant reservoir out of the way. Draining of the washer fluid, power steering fluid and engine coolant is not required. 10. Remove the windshield washer reservoir, power steering reservoir and the engine coolant reservoir and position them out of the way. 11. Remove the nut (1) that secures the refrigerant line retaining bracket (2) to the right front strut tower (5). 12. On RHD models, disengage the retainers that secure the power brake booster vacuum supply hose to the dash panel and position the vacuum line out of the way. 13. Remove the bolt (3) that secures the A/C liquid and suction line assembly (4) to the A/C evaporator (6). 14. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals. 15. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports. 16. Remove the A/C liquid and suction line assembly from the engine compartment. Lower A/C Suction Line 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant systemSee: Service and Repair/Refrigerant System Recovery. 3. Raise and support the vehicle. 4. Remove the right front wheel See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Removal. 5. Remove the three push-pin retainers (1) and three screws (2) that secure the front portion of the right front wheelhouse splash shield (3) to body (4) and position the front of the wheelhouse splash shield out of the way to gain access to the A/C accumulator. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5870 6. Remove the nut (2) that secures the lower A/C suction line (3) to the A/C accumulator (1). 7. Disconnect the lower A/C suction line from the A/C accumulator and remove and discard the O-ring seal and gasket. 8. Install plugs in, or tape over the opened suction line fitting and the accumulator port. NOTE: 5SE12 A/C compressor shown. 6SEU16 compressor similar. 9. Remove the nut (1) that secures the lower A/C suction line (2) to the A/C compressor (3). 10. Disconnect the lower A/C suction line from the A/C compressor and remove and discard the O-ring seal and gasket. 11. Install plugs in, or tape over the opened suction line fitting and the compressor port. 12. Remove the lower A/C suction line from the engine compartment. A/C Suction Line - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Service and Repair/Refrigerant Oil Level . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: LHD model shown in illustrations. RHD model similar. Upper A/C Suction Line Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5871 1. Position the A/C liquid and suction line assembly (4) into the engine compartment. 2. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports. 3. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the A/C liquid and suction line assembly to the A/C evaporator (6). 5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 12 Nm (105 in. lbs.). 6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose to the dash panel. 7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5). Tighten the nut to 4.5 Nm (40 in. lbs.). 8. Install the windshield washer reservoir, power steering reservoir and the engine coolant reservoir. 9. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment. 10. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 Nm (10 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5872 NOTE: Illustration shown with front fascia removed for clarity. 11. Raise and support the vehicle. 12. Remove the tape or plugs from the liquid line fitting and the condenser port. 13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 14. Reach up through the opening in the bottom of the front fascia and connect the A/C liquid line (1) to the A/C condenser (2) and install the retaining nut (3). Tighten the nut to 5 Nm (44 in. lbs.). 15. Install the A/C accumulator See: Accumulator HVAC/Service and Repair/Accumulator Installation. 16. Lower the vehicle. 17. Reconnect the negative battery cable. 18. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate 19. Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Service and Repair/Refrigerant Oil Level. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 20. Charge the A/C system See: Service and Repair/Refrigerant System Charge. Lower A/C Suction Line NOTE: 5SE12 A/C compressor shown. 6SEU16 compressor similar. 1. Position the lower A/C suction line (2) into the engine compartment. 2. Remove the tape or plugs from the suction line fitting and the compressor port. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the lower A/C suction line to the A/C compressor (3). 5. Install the nut (1) that secures the A/C suction line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line - Removal > Page 5873 6. Remove the tape or plugs from the suction line fitting and the accumulator port. 7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the lower A/C suction line (3) to the A/C accumulator (1). 9. Install the nut (2) that secures the lower A/C suction line to the A/C accumulator. Tighten the nut to 5 Nm (44 in. lbs.). 10. Reposition the front of the right front wheel house splash shield (3) to the body (4) and install the three push-pin retainers (1) and the three screws (2). Tighten the screws securely. 11. Install the right front wheel See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation. 12. Lower the vehicle. 13. Reconnect the negative battery cable. CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 14. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 15. Adjust the refrigerant oil level See: Service and Repair/Refrigerant Oil Level. 16. Charge the A/C system See: Service and Repair/Refrigerant System Charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Description and Operation Housing Assembly HVAC: Description and Operation DESCRIPTION NOTE: LHD model shown RHD model similar. All models are equipped with a common HVAC housing assembly that combines A/C and heating capabilities into a single unit mounted within the passenger compartment. The HVAC housing assembly consists of three separate housings: - HVAC housing - The HVAC housing (1) is mounted to the dash panel behind the instrument panel and contains the A/C evaporator. The HVAC housing consists of an upper and a lower housing that are attached together and has mounting provisions for the air inlet housing, blower motor and the air distribution housing. - Air distribution housing - The air distribution housing (2) is mounted to the rear of the HVAC housing and contains the heater core, blend-air and mode-air doors and door linkage. - Air inlet housing - The air inlet housing (3) is mounted to the passenger side end of the HVAC housing. The air inlet housing contains the recirculation-air door and actuator when equipped with A/C. The heating-A/C system is a blend-air type system. The blend-air door controls the amount of conditioned air that is allowed to flow through, or around, the heater core. The A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C evaporator to cool and dehumidify the incoming air prior to blending it with the heated air. A temperature control determines the discharge air temperature by operating the temperature control cable, which moves the blend-air door. This allows an almost immediate control of the output air temperature of the system. The mode door cable operates the mode-air doors which direct the flow of the conditioned air out the various air outlets, depending on the mode selected. When equipped with A/C, the recirculation door actuator operates the recirculation-air door which closes off the fresh air intake and recirculates the air already inside the vehicle. The electric recirculation door actuator and the blower motor are connected to the vehicle electrical system by the instrument panel wire harness. The blower motor controls the velocity of air flowing through the HVAC housing assembly by spinning the blower wheel within the HVAC housing at the selected speed by use of the blower motor resistor, which is located in the dash panel in the engine compartment. The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors. The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement Housing Assembly HVAC: Removal and Replacement Air Distribution Housing Removal HOUSING-AIR DISTRIBUTION WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors. NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar. 1. Remove the HVAC housing assembly and place it on a workbench See: HVAC Housing Removal. 2. Remove all of the floor distribution ducts from the air distribution housing (5) See: Air Duct/Service and Repair/Floor Distribution Duct - Removal. NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 3. Remove the foam seal (1) from the flange (2) located on the front of the HVAC housing (9). 4. Remove the screw (10) that secures the flange to the front of the HVAC housing and remove the flange. 5. Remove the screw (3) that secures the retaining bracket (4) for the heater core tubes (8) to the left side of the air distribution housing. 6. On RHD models, remove the air distribution housing from the HVAC housing See: HVAC Housing - Removal 7. Carefully pull the heater core (6) out of the driver side of the air distribution housing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5879 NOTE: Illustration shown with heater core and tubes removed from view for clarity. 8. Remove the two metal retaining clips (3) that secure the bottom of air distribution housing (2) to the HVAC housing (4). 9. Remove the seven screws (1) that secure the air distribution housing to the rear of the HVAC housing. 10. Remove the air distribution housing from the rear of the HVAC housing. 11. If required, disassemble the air distribution housing See: Overhaul/Disassembly. Air Distribution Housing Installation HOUSING-AIR DISTRIBUTION NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar. NOTE: Illustration shown with heater core and tubes removed from view for clarity. 1. Position the air distribution housing (2) onto the rear of the HVAC housing (4). 2. Install the two metal retaining clips (3) that secure the bottom of the air distribution housing to the HVAC housing. 3. Install the seven screws (1) that secure the air distribution housing to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5880 4. Carefully install the heater core (6) into the left side of the air distribution housing (5). 5. On RHD models, install the air distribution housing onto the HVAC housing (9) See: HVAC Housing Installation. 6. Install the retaining bracket (4) and screw (3) that secure the heater core tubes (8). Tighten the screw to 1.2 Nm (10 in. lbs.) 7. Install the flange (2) that secures the heater core tubes to the front of the HVAC housing. 8. Install the screw (10) that secures the flange to the HVAC housing. Tighten the screw to 1.2 Nm (10 in. lbs.). NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 9. Install the foam seal (1) onto the flange. 10. Install all of the floor distribution ducts onto the air distribution housing See: Air Duct/Service and Repair/Floor Distribution Duct - Installation. NOTE: If the heater core is being replaced, flush the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair . 11. Install the HVAC housing assembly See: HVAC Housing - Installation. Air Inlet Housing Removal HOUSING-AIR INLET WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. NOTE: LHD model shown. RHD model similar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5881 1. Remove the HVAC housing assembly and place it on a workbench See: HVAC Housing Removal. 2. If equipped, remove the particulate air filter See: Cabin Air Filter/Service and Repair/Removal and Replacement/Particulate Air Filter - Removal. 3. Remove the four screws (1) that secure the air inlet housing (2) to the top of the HVAC housing (3). 4. Disengage the two plastic retaining tabs (4) that secure the air inlet housing to the HVAC housing and remove the inlet housing from the HVAC housing. 5. If required, disassemble the air inlet housing See: Overhaul/Disassembly. Air Inlet Housing Installation HOUSING-AIR INLET NOTE: LHD model shown. RHD model similar. 1. Install the air inlet housing (2) onto the top of the HVAC housing (3) and engage the two plastic retaining tabs (4). Make sure the retaining tabs are fully engaged. 2. Install the four screws (1) that secure the air inlet housing to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 3. If equipped, install the particulate air filter See: Cabin Air Filter/Service and Repair/Removal and Replacement/Particulate Air Filter - Installation. 4. Install the HVAC housing assembly See: HVAC Housing - Installation. Air Inlet Screen Removal SCREEN-AIR INLET NOTE: LHD model shown. RHD model similar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5882 1. Remove the cowl grille screen See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Cover - Removal. 2. Disengage the three push-in retainers (1) that secure the HVAC housing air inlet screen (2) to the cowl panel (3) and remove the screen. Air Inlet Screen Installation SCREEN-AIR INLET NOTE: LHD model shown. RHD model similar. 1. Position the HVAC housing air inlet screen (2) to the cowl panel (3) and fully engage the three push-in retainers (1) that secure the screen to the panel. 2. Install the cowl grille screen See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Cover - Installation. HVAC Housing - Removal HOUSING-HVAC WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the heater core, A/C evaporator, air intake housing and the mode-air and blend-air doors. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5883 NOTE: LHD model shown in illustrations. RHD model similar. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Partially drain the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 4. Remove the three nuts (1) that secure the heat shield (3) to the studs (2) located on the dash panel in the engine compartment and remove the heat shield. 5. Remove the bolt (1) that secures the A/C liquid and suction line assembly (2) to the A/C evaporator (3). 6. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and discard the dual-plane seals. 7. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports. 8. Disconnect the heater hoses (4) from the heater core tubes. Install plugs in, or tape over the opened heater core tubes to prevent coolant spillage during housing removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5884 NOTE: Make sure to remove the five bolts that secure the HVAC housing to the instrument panel support prior to removing the instrument panel from the vehicle. 9. Remove the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Removal. 10. Remove the rear floor ducts See: Air Duct/Service and Repair/Floor Distribution Duct Removal. 11. Remove the condensation drain tube See: Evaporator Drain Tube/Service and Repair/Condensation Drain Tube - Removal. 12. Remove the nut (1) that secures the passenger side of the HVAC housing (2) to the dash panel (3). NOTE: Use care to ensure that the interior is covered in case of loss of residual fluids from the heater and evaporator cores. 13. Pull the HVAC housing rearward and remove the HVAC housing assembly from the passenger compartment. HVAC Housing - Installation HOUSING - HVAC NOTE: LHD model shown in illustrations. RHD model similar. 1. Position the HVAC housing assembly (2) to the dash panel (3). Be certain that the passenger side of the HVAC housing is correctly located over the dash panel mounting stud. 2. Install the nut (1) that secures the HVAC housing to the passenger compartment side of dash panel. Tighten the nut to 4.5 Nm (40 in. lbs.). 3. Install the condensation drain tube See: Evaporator Drain Tube/Service and Repair/Condensation Drain Tube - Installation. 4. Install the rear floor ducts See: Air Duct/Service and Repair/Floor Distribution Duct - Installation. 5. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5885 6. Remove the previously installed plugs or caps and connect the heater hoses (4) to the heater core tubes. 7. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports. 8. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 9. Connect the A/C liquid and suction line assembly (2) to the A/C evaporator (3). 10. Install the bolt (1) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 12 Nm (105 in. lbs.). 11. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment. 12. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 Nm (10 in. lbs.). 13. Reconnect the negative battery cable. 14. If the heater core is being replaced, flush the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 15. Refill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 16. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 17. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5886 Housing Assembly HVAC: Overhaul Air Distribution Housing HOUSING-AIR DISTRIBUTION NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors. NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar. 1. Remove the HVAC housing assembly and place it on a workbench See: Removal and Replacement/HVAC Housing - Removal. 2. Remove the air distribution housing (2) from the HVAC housing (1) See: Removal and Replacement/HVAC Housing - Removal. 3. If equipped with the 2.0L diesel engine, remove the electric positive temperature coefficient (PTC) heater unit from the air distribution housing . 4. Remove the heater core from the air distribution housing See: Heater Core/Service and Repair/Removal. 5. Remove the temperature control cable (1) from the left side of the air distribution housing (2) See: Air Door/Air Door Cable/Service and Repair/Temperature Door Cable - Removal. 6. Remove the screw and washer (5) that secures the blend door cable lever (6) to the air distribution housing and remove the cable lever. NOTE: To remove the blend door pivot lever, disengage the retaining tab and pull the lever straight out of the air distribution housing. 7. Remove the blend door pivot lever (3) from the end of the blend door pivot shaft (4) and remove the pivot lever. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5887 8. Remove the mode door cable (1) from the right side of the air distribution housing (2) See: Air Door/Air Door Cable/Service and Repair/Mode Door Cable - Removal. 9. Remove the screw and washer (3) that secure the mode door cam (4) to the air distribution housing and remove the cam. NOTE: If any foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced. 10. Carefully cut the two foam seals (1) along the parting line (2) of the two halves of the air distribution housing (3). If either seal is deformed or damaged, it must be replaced. 11. Remove the five screws (4) and one metal clip (5) that secure the two halves of the air distribution housing together. 12. Disengage the three plastic retaining tabs (6) that secure the two halves of the air distribution housing together and carefully separate the housing. NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced. 13. Disengage the air door(s) (1, 2, 3 and 4) from the mode door levers and remove the air doors from the air distribution housing (5). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5888 NOTE: To remove the mode door levers, disengage the retaining tabs on the inside of the air distribution housing and pull the levers straight out of the housing. 14. Remove the four mode door levers (1, 2, 3 and 4) from the right side of the air distribution housing (5). Air Inlet Housing HOUSING-AIR INLET NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar. 1. Remove the HVAC housing assembly and place it on a workbench See: Removal and Replacement/HVAC Housing - Removal. 2. Remove the air inlet housing (3) from the HVAC housing (1)See: Removal and Replacement/HVAC Housing - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5889 3. Remove the two screws (1) that secure the recirculation door actuator (2) to the right side of the air inlet housing (3) and remove the actuator. 4. To remove the recirculation door pivot shaft adapter from the right end of the recirculation-air door, first carefully push down on the tab of the door lever pivot shaft adapter located inside of the air inlet housing, then pull the pivot shaft adapter straight out of the end of the recirculation-air door pivot shaft. NOTE: If the foam seal on the air inlet housing is deformed or damaged, the seal must be replaced. NOTE: If a rubber seal on the recirculation air-door is deformed or damaged, the air-door must be replaced. 5. Carefully pinch the two ends of the recirculation air-door together and remove the air-door from the air inlet housing. If the seal on the recirculation air-door is deformed or damaged, the air-door must be replaced. HVAC Housing HOUSING-HVAC NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator. NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5890 1. Remove the HVAC housing assembly and place it on a workbench See: Removal and Replacement/HVAC Housing - Removal. 2. Remove the air distribution housing (2) from the HVAC housing (1) See: Removal and Replacement/HVAC Housing - Removal. 3. Remove the air inlet housing (3) from the HVAC housing See: Removal and Replacement/HVAC Housing - Removal. 4. Remove the three screws (1) that secure the wire lead bracket (2) and the blower motor (3) to the bottom of the HVAC housing (4) and remove the blower motor and wire lead bracket. 5. Remove the two screws (5) that secure the blower motor resistor (6) to the bottom of the HVAC housing and remove the resistor. 6. Using needle nose pliers (1), disengage the two retaining tabs (2) that secure the evaporator temperature sensor (3) to the driver side of the HVAC housing (4) and remove the sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5891 NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced. 7. Carefully remove the foam seal (2) from the front of the two halves of the HVAC housing (4). If the seal is deformed or damaged, it must be replaced. 8. Remove the nine screws (3) and three metal clips (5) that secure the two halves of the HVAC housing together. 9. Disengage the nine plastic retaining tabs (1) that secure the two halves of the HVAC housing together and separate the housing. NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced. 10. Carefully lift the A/C evaporator (1) and the foam insulator (2) out of the lower half of the HVAC housing (3). NOTE: If the seal around the evaporator tube tapping block is deformed or damaged, the seal must be replaced. 11. If required, remove the seal (4) from around the evaporator tube tapping block (5). Air Distribution Housing HOUSING-AIR DISTRIBUTION NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5892 1. Install the four mode door levers (1, 2, 3 and 4) onto the right side of the air distribution housing (5) Make sure the lever retaining tabs are fully engaged to the housing. NOTE: Properly position the air doors within the air distribution housing by first aligning the four mode door levers to the scribe lines located on the right outer side of the air distribution housing. Then, install the air doors onto the mode door levers with the UP mark on each air door facing toward the top of the housing. NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced. 2. Align the four mode door levers to the scribe lines on the right outer side of the air distribution housing (5) and install the air door(s) (1, 2, 3 and 4) onto the mode door levers with the UP mark on each air door facing toward the top of the housing. 3. Align the air door(s) with the pivot shaft hole(s) in the air distribution housing (3) and install the two halves of the housing together. Make sure the three plastic retaining tabs (6) are fully engaged. 4. Install the five screws (4) and one metal clip (5) that secure the two halves of the air distribution housing together. Tighten the screws to 2.2 Nm Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5893 (20 in lbs.). Make sure the metal clip is fully engaged to the housing halves. NOTE: If any foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced. 5. Inspect the foam seals (1), especially at the parting line (2). If a foam seal is deformed or damaged, it must be replaced. NOTE: Align the pins on the mode door levers with the grooves in the back of the mode door cam prior to installation of the cam. 6. Align the mode door levers on the right side of the air distribution housing (2) to the mode door cam (4) and install the cam onto the housing. Make sure the levers are correctly engaged to the cam. 7. Install the screw and washer (3) that secure the mode door cam to the air distribution housing. Tighten the screw to 0.6 Nm (5 in. lbs.). 8. Install the mode door cable (1)See: Air Door/Air Door Cable/Service and Repair/Mode Door Cable - Installation. 9. Install the blend door pivot lever (3) onto the end of the blend door pivot shaft (4) located on the left side of the air distribution housing (2). Make sure the lever retaining tab is fully engaged to the pivot shaft. NOTE: Align the pin on the blend door lever with the groove in the pivot lever prior to installation of the blend door lever. 10. Install the blend door lever (6) onto the air distribution housing. Make sure the levers are correctly aligned to each other. 11. Install the screw and washer (5) that secure the blend door lever to the air distribution housing. Tighten the screw to 0.6 Nm (5 in. lbs.). 12. Install the temperature control cable (1) See: Air Door/Air Door Cable/Service and Repair/Temperature Door Cable - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5894 13. If equipped with the 2.0L diesel engine, install the electric positive temperature coefficient (PTC) heater unit into the air distribution housing . 14. Install the heater core into the air distribution housing (2) See: Heater Core/Service and Repair/Installation. 15. Install the air distribution housing onto the HVAC housing (1) See: Removal and Replacement/HVAC Housing - Installation. 16. Install the HVAC housing assembly See: Removal and Replacement/HVAC Housing - Installation. Air Inlet Housing HOUSING-AIR INLET NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar. 1. Carefully install the recirculation-air door (1) into the air inlet housing (2) by pinching the two ends of the air-door together and aligning the pivot shafts of the air-door to the pivot shaft holes in the air inlet housing. NOTE: Install the recirculation door pivot shaft adapter by carefully pushing it straight into the end of the recirculation door pivot shaft. 2. Install the recirculation door pivot shaft adapter (3) into the right side pivot shaft of the recirculation air-door. Make sure the adapter is fully engaged to the pivot shaft. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5895 3. Install the recirculation door actuator (1) onto the right side of the air inlet housing (2). If necessary, rotate the actuator slightly to align the splines of the actuator output shaft (3) with those on the recirculation door pivot shaft adapter (4). 4. Install the air inlet housing (3) onto the HVAC housing (1) See: Removal and Replacement/HVAC Housing - Installation. 5. Install the HVAC housing assembly See: Removal and Replacement/HVAC Housing - Installation. HVAC Housing HOUSING-HVAC NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar. 1. If removed, install the seal (4) onto the evaporator tube tapping block (5). NOTE: Make sure that the foam insulator is properly positioned in the HVAC housing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5896 2. Carefully install the A/C evaporator (1) and foam insulator (2) into the lower half of the HVAC housing (3). 3. Install the two halves of the HVAC housing (4) together and engage the nine plastic retaining tabs (1). Make sure the retaining tabs are fully engaged. 4. Install the nine screws (3) and three metal clips (5) that secure the two halves of the HVAC housing together. Tighten the screws to 1.2 Nm (10 in lbs.). Make sure the metal clips are fully engaged to the housing halves. 5. Install the foam seal (2) onto the front of the two HVAC housing halves. 6. Install the evaporator temperature sensor (1) into the driver side of the HVAC housing (2). Make sure the retaining tabs (3) are fully engaged to the housing. 7. Position the blower motor (3) into the bottom of the HVAC housing (4). 8. Install the wire lead bracket (2) and the three screws (1) that secure the blower motor to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 5897 9. Position the blower motor resistor (6) into the HVAC housing. 10. Install the two screws (5) that secure the blower motor resistor to the HVAC housing. Tighten the screws to 1.2 Nm (10 in. lbs.). 11. Install the air inlet housing (3) onto the HVAC housing (1) See: Removal and Replacement/HVAC Housing - Installation. 12. Install the air distribution housing (2) onto the HVAC housing See: Removal and Replacement/HVAC Housing - Installation. NOTE: If the heater core is being replaced, flush the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair . 13. Install the HVAC housing assembly See: Removal and Replacement/HVAC Housing Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications REFRIGERANT CHARGE CAPACITY REFRIGERANT CHARGE CAPACITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 5902 Refrigerant: Fluid Type Specifications Type...................................................................................................................................................... .........................................................................R-134a Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Description and Operation > A/C Refrigerant Refrigerant: Description and Operation A/C Refrigerant A/C REFRIGERANT The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a nontoxic, nonflammable, clear and colorless liquefied gas. CAUTION: R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure. The A/C refrigerant system is filled-for-life at the factory and requires no regular maintenance. Although not required at specific intervals, the charge level should be checked if system performance deteriorates or if a noise or leak is suspected See: Testing and Inspection. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Description and Operation > A/C Refrigerant > Page 5905 Refrigerant: Description and Operation Refrigerant - Description DESCRIPTION The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming . See: Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Description and Operation > A/C Refrigerant > Page 5906 Refrigerant: Description and Operation Refrigerant - Operation OPERATION R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery Refrigerant: Service and Repair Refrigerant System - Recovery REFRIGERANT SYSTEM RECOVERY WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. When servicing the A/C system, use an R-134a refrigerant recovery/recycling/charging station (1) that meets SAE standard J2788. Per SAE standard J2788, refrigerant recovery stations must recover 95% of the refrigerant system within 30 minutes at 21.1° C (70° F) and be able to measure the amount of refrigerant removed from the system to an accuracy of 28 grams (1 oz.). See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 5909 Refrigerant: Service and Repair Refrigerant System - Evacuate REFRIGERANT SYSTEM EVACUATE CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. NOTE: Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficult to remove and will cause a reliability problem with the A/C compressor. If an A/C compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C compressor be used. This will eliminate the possibility of contaminating the refrigerant system. If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system: NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. 1. Recover the refrigerant system See: Service and Repair/Refrigerant System Recovery. 2. With the engine OFF, connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment See: Service and Repair/Refrigerant System Recovery. Do not operate the engine with a vacuum on the A/C system. 3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge reads to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater) for 30 minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes. 4. Close all valves. Turn off and disconnect the vacuum pump. 5. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 5910 Refrigerant: Service and Repair Refrigerant System - Charge REFRIGERANT SYSTEM CHARGE WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The Underhood HVAC Specification Label contains the refrigerant fill specification of the vehicle being serviced. After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system. Use an R-134a refrigerant recovery/recycling/charging station (1) that meets SAE Standard J2788 to charge the refrigerant system with R-134a refrigerant. See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. CHARGING PROCEDURE CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. See the equipment manufacturer instructions for more information. 1. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 2. A manifold gauge set and an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 should be connected to the refrigerant system. 3. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station See: Specifications/Capacity Specifications. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. 4. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. 5. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 6. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is operating and the blower motor is running at its lowest speed setting. Run the engine at a steady high idle (about 1400 rpm). 7. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system. WARNING: Take care not to open the discharge (high pressure) valve at this time. Failure to follow this warning may result in possible serious or fatal injury. 8. Disconnect the charging station and manifold gauge set from the refrigerant system service ports. 9. Reinstall the caps onto the refrigerant system service ports. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES - 5SE12 A/C COMPRESSOR REFRIGERANT OIL CAPACITIES - 6SEU16 A/C COMPRESSOR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 5915 Refrigerant Oil: Fluid Type Specifications The A/C compressor used in this vehicle is designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil in the refrigerant system. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Refrigerant Oil - Description Refrigerant Oil: Description and Operation Refrigerant Oil - Description DESCRIPTION The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils and should never be introduced to an R-134a refrigerant system. There are different PAG oils available and each contain a different additive package. Always use only the type of refrigerant oil recommended for the A/C compressor in the vehicle. CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor See: Service and Repair/Refrigerant Oil Level . Failure to properly adjust the refrigerant oil level can prevent the A/C system from operating as designed and can cause serious A/C compressor damage. The A/C compressor used in this vehicle is designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil in the refrigerant system. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Refrigerant Oil - Description > Page 5918 Refrigerant Oil: Description and Operation Refrigerant Oil - Operation OPERATION After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Page 5919 Refrigerant Oil: Service and Repair REFRIGERANT OIL LEVEL When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The A/C accumulator, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. Drain the refrigerant oil from the A/C compressor using the procedures described below. Failure to properly drain the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. CAUTION: ND-8 PAG refrigerant oil is used in the A/C system. Only refrigerant oil of the same type should be used to service this R-134a A/C system. Do not use any other refrigerant oil. The refrigerant oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from moisture and dirt. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the amount of refrigerant oil being removed during the recovery process. This amount of refrigerant oil should always be added back into the refrigerant system. Refer to the reclaim/recycling equipment manufacturers instructions. It will not be necessary to check the oil level within the A/C refrigerant system or to add oil, unless there has been an oil loss. A refrigerant oil loss may occur due to component replacement or a rupture or leak from a refrigerant line, connector fitting, component or component seal. If a leak does occurs, add 30 milliliters (1 fluid ounce) of the recommended refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when an A/C accumulator, A/C evaporator or A/C condenser is replaced. See Refrigerant Oil Capacities charts. The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor installation. See COMPRESSOR OIL DRAIN PROCEDURES. REFRIGERANT OIL CAPACITIES - 5SE12 A/C COMPRESSOR REFRIGERANT OIL CAPACITIES - 6SEU16 A/C COMPRESSOR COMPRESSOR OIL DRAIN PROCEDURE - DENSO 5SE12 A/C COMPRESSOR CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. The refrigerant oil in the Denso 5SE12 A/C compressor can only be drained using the procedure below. Failure to properly drain the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. NOTE: When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine how much oil should be Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Page 5920 removed from the new A/C compressor (example: new 5SE12 A/C compressor and an accumulator requires 80 ml. (2.7 oz.) of oil to be added to the system. 120 ml. (4.1 oz.) of oil is in new compressor. 120 ml. (4.1 oz.) minus 80 ml. (2.7 oz.) equals 40 ml. (1.4 oz.) oil to be drained from new compressor). If the Denso 5SE12 A/C compressor is being replaced, some refrigerant oil must first be drained from the new A/C compressor. The 5SE12 A/C compressor is filled with 120 milliliters (4.1 oz.) from the factory. Drain 70 milliliters (2.4 oz.) of refrigerant oil from the new 5SE12 compressor. Use the following procedure to drain and measure refrigerant oil from the Denso 5SE12 A/C compressor. 1. Place the new A/C compressor (1) on a workbench. 2. Position the A/C compressor so that the refrigerant oil can drain out of the suction port (2) into a suitable clean measured container. Hold the A/C compressor in this position until no more oil comes out of the compressor port. 3. Reposition the A/C compressor (1) so that the pulley (2) is facing upward and slowly rotate the compressor pulley clockwise one full turn. CAUTION: The 5SE12 A/C compressor is filled with 120 milliliters (4.1 oz.) from the factory. Drain 70 milliliters (2.4 oz.) of refrigerant oil from the new 5SE12 compressor. 4. Repeat steps 2 and 3 at least seven times or until the required amount of refrigerant oil is drained from the new compressor. CAUTION: Failure to properly adjust the refrigerant oil level prior to installation of a replacement compressor can prevent the A/C system from operating as designed and cause serious compressor damage. 5. Install the new A/C compressor onto the engine See: Compressor HVAC/Service and Repair/A/C Compressor - Installation. COMPRESSOR OIL DRAIN PROCEDURE - DENSO 6SEU16 A/C COMPRESSOR CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. The refrigerant oil in the Denso 6SEU16 A/C compressor can only be drained using the procedure below. Failure to properly drain the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. If the Denso 6SEU16 A/C compressor is being replaced, some refrigerant oil must first be drained from the new A/C compressor. The 6SEU16 A/C compressor is filled with 100 milliliters (3.4 oz.) from the factory. Drain 60 milliliters (2.1 oz.) of refrigerant oil from the new 6SEU16 compressor. Use Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Page 5921 the following procedure to drain and measure refrigerant oil from the Denso 6SEU16 A/C compressor. 1. Place the new A/C compressor (2) on a workbench and remove the drain plug (1). CAUTION: The 6SEU16 A/C compressor is filled with 100 milliliters (3.4 oz.) from the factory. Drain 60 milliliters (2.1 oz.) of refrigerant oil from the new 6SEU16 compressor when replacing only the compressor. NOTE: When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine how much oil should be removed from the new A/C compressor (example: new 6SEU16 A/C compressor and an accumulator requires 60 ml. (2.1 oz.) of oil to be added to the system. 100 ml. (3.4 oz.) of oil is in new compressor. 100 ml. (3.4 oz.) minus 60 ml. (2.1 oz.) equals 40 ml. (1.4 oz.) oil to be drained from new compressor). 2. Position the A/C compressor so that the refrigerant oil can drain out of the drain port into a suitable clean measured container. Hold the A/C compressor in this position until the required amount of refrigerant oil is drained from the new compressor. CAUTION: Failure to properly adjust the refrigerant oil level prior to installation of a replacement compressor can prevent the A/C system from operating as designed and cause serious compressor damage. 3. Reinstall the drain plug. Tighten the drain plug securely. 4. Install the new A/C compressor onto the engine See: Compressor HVAC/Service and Repair/A/C Compressor - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5925 Refrigerant Pressure Sensor / Switch: Diagrams Connector - (ENGINE COMPARTMENT) 4 WAY TRANSDUCER-A/C PRESSURE - (ENGINE COMPARTMENT) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer - Description Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Transducer Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer - Description > Page 5928 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Transducer Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line. The internal resistance of the A/C pressure transducer changes in response to the pressures it monitors. The Totally Integrated Power Module (TIPM) provides a five volt reference signal and a sensor ground to the A/C pressure transducer. The TIPM then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure and sends a message to the Powertrain Control Module (PCM) or Engine Control Module (ECM) (depending on engine application) over the Controller Area Network (CAN) C BUS. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the swash plate within the A/C compressor and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM adjusts the swash plate to nearly a zero degree angle (low compressor displacement) when high side pressure rises above 3130 kPa (454 psi) and readjusts the swash plate to a greater angle (higher compressor displacement) when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer also reduces the swash plate angle if the high side pressure drops below 200 kPa (29 psi) and will increase the swash plate angle when the high side pressure rises above 234 - 262 kPa (34 - 38 psi). When the refrigerant pressure rises above 1655 kPa (240 psi) the PCM will actuate the cooling fan. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Transducer - Removal Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Transducer - Removal REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. NOTE: Typical A/C pressure transducer shown. 1. Disconnect and isolate the negative battery cable. 2. Carefully pull the top of the fascia forward to gain access to the A/C pressure transducer (2) See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Removal. 3. Reach down through the opening between the A/C condenser and the front fascia and disconnect the wire harness connector (1) from the A/C pressure transducer located on the A/C discharge line (3). 4. Remove the A/C pressure transducer from the A/C discharge line and remove and discard the O-ring seal (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Transducer - Removal > Page 5931 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Transducer - Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. NOTE: Typical A/C pressure transducer shown. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the A/C discharge line (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reinstall the top of the front fascia See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Installation. 5. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5936 Ambient Temperature Sensor / Switch HVAC: Diagrams Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-AMBIENT AIR TEMPERATURE - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5940 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 5941 Evaporator Temperature Sensor / Switch: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SENSOR-EVAPORATOR TEMPERATURE - (INSTRUMENT PANEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Evaporator Temperature Sensor - Description Evaporator Temperature Sensor / Switch: Description and Operation Evaporator Temperature Sensor - Description DESCRIPTION The evaporator temperature sensor measures the temperature of the conditioned air downstream of the A/C evaporator. The evaporator temperature sensor is an electrical thermistor (1) mounted on the end of a molded plastic housing (2) that is inserted into the driver side of the HVAC housing near the coldest point of the A/C evaporator. The evaporator temperature sensor is retained in the HVAC housing by two integral retaining tabs (3) and is connected to the vehicle electrical system by use of a wire lead and connector (4) with two terminals. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Evaporator Temperature Sensor - Description > Page 5944 Evaporator Temperature Sensor / Switch: Description and Operation Evaporator Temperature Sensor - Operation OPERATION The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an input signal to the Cabin Compartment Node (CCN). The CCN uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the CCN through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The CCN uses the monitored voltage reading as an indication of evaporator temperature. The CCN is programmed to respond to this input by requesting the Powertrain Control Module (PCM) or the Engine Control Module (ECM) (depending on engine application) to cycle the A/C clutch off and on as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing See: Compressor HVAC/Description and Operation/A/C Compressor - Operation. The evaporator temperature sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The evaporator temperature sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Evaporator Temperature Sensor - Removal Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Illustration shown with air distribution housing removed for clarity. NOTE: It is not necessary to remove and disassemble the HVAC housing to service the evaporator temperature sensor. The evaporator temperature sensor can be removed for service from underneath the instrument panel. 1. Disconnect and isolate the negative battery cable. 2. Reach up under the driver side of the instrument panel and disconnect the electrical connector for the evaporator temperature sensor (1) from the instrument panel wire harness. 3. Using needle nose pliers, disengage the two retaining tabs (3) that secure the evaporator temperature sensor to the HVAC housing (2) by carefully pulling the sensor straight out of the side of the HVAC housing. 4. Route the electrical connector and wire lead of the evaporator temperature sensor out from under the heater core tubes and remove the sensor from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Evaporator Temperature Sensor - Removal > Page 5947 Evaporator Temperature Sensor / Switch: Service and Repair Evaporator Temperature Sensor Installation INSTALLATION NOTE: Illustration shown with air distribution housing removed for clarity. 1. Route the electrical connector and wire lead of the evaporator temperature sensor (1) under the heater core tubes located on the driver side of the HVAC housing (2). 2. Install the evaporator temperature sensor into the driver side of the HVAC housing. Make sure the retaining tabs (3) are fully engaged to the housing. 3. Connect the electrical connector for the evaporator temperature sensor to the instrument panel wire harness. 4. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5951 Refrigerant Pressure Sensor / Switch: Diagrams Connector - (ENGINE COMPARTMENT) 4 WAY TRANSDUCER-A/C PRESSURE - (ENGINE COMPARTMENT) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer - Description Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Transducer Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Transducer - Description > Page 5954 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Transducer Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line. The internal resistance of the A/C pressure transducer changes in response to the pressures it monitors. The Totally Integrated Power Module (TIPM) provides a five volt reference signal and a sensor ground to the A/C pressure transducer. The TIPM then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure and sends a message to the Powertrain Control Module (PCM) or Engine Control Module (ECM) (depending on engine application) over the Controller Area Network (CAN) C BUS. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the swash plate within the A/C compressor and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM adjusts the swash plate to nearly a zero degree angle (low compressor displacement) when high side pressure rises above 3130 kPa (454 psi) and readjusts the swash plate to a greater angle (higher compressor displacement) when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer also reduces the swash plate angle if the high side pressure drops below 200 kPa (29 psi) and will increase the swash plate angle when the high side pressure rises above 234 - 262 kPa (34 - 38 psi). When the refrigerant pressure rises above 1655 kPa (240 psi) the PCM will actuate the cooling fan. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Transducer - Removal Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Transducer - Removal REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. NOTE: Typical A/C pressure transducer shown. 1. Disconnect and isolate the negative battery cable. 2. Carefully pull the top of the fascia forward to gain access to the A/C pressure transducer (2) See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Removal. 3. Reach down through the opening between the A/C condenser and the front fascia and disconnect the wire harness connector (1) from the A/C pressure transducer located on the A/C discharge line (3). 4. Remove the A/C pressure transducer from the A/C discharge line and remove and discard the O-ring seal (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Pressure Transducer - Removal > Page 5957 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Transducer - Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. NOTE: Typical A/C pressure transducer shown. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the A/C discharge line (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reinstall the top of the front fascia See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Installation. 5. Reconnect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation DESCRIPTION Refrigerant system service ports are used to recover, recycle, evacuate, charge and test the A/C refrigerant system. Unique sizes are used on the two service ports for the R-134a refrigerant system to ensure the system is not accidentally contaminated with R-12 refrigerant or by service equipment used for R-12 refrigerant. The high side service port (1) is located on the A/C discharge line (2) in front of the engine, below the upper radiator hose (3). The low side service port (1) is located on the A/C liquid line (2) near the right front strut tower (3). Both the high side and low side A/C service port valve cores are serviceable. NOTE: The protective cap aids in service port sealing and helps protect the refrigerant system from contamination. Remember to always reinstall the protective cap onto the service port when refrigerant system service is complete. Each of the service ports has a threaded plastic protective cap installed over it from the factory. The service port caps are serviceable items. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and Repair > Service Port Valve Core - Removal Service Port HVAC: Service and Repair Service Port Valve Core - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in serious or fatal injury. NOTE: Typical A/C service port shown. 1. Remove the protective cap (1) from the service port (2). 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Using a Schrader-type valve core tool, remove the valve core (3) from the service port. 4. Install a plug in, or tape over the opened service port(s). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and Repair > Service Port Valve Core - Removal > Page 5963 Service Port HVAC: Service and Repair Service Port Valve Core - Installation INSTALLATION NOTE: Typical A/C service port shown. 1. Lubricate the valve core (3) with clean refrigerant oil prior to installation. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 2. Remove the tape or plug from the service port (2). CAUTION: A valve core that is not fully seated in the A/C service port can result in damage to the valve during refrigerant system evacuation and charge. Such damage may result in a loss of system refrigerant while uncoupling the charge adapters. 3. Using a Schrader-type valve core tool, install and tighten the valve core into the service port(s). CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage. 4. Evacuate and charge the refrigerant system See: Service and Repair/Refrigerant System Charge. NOTE: The protective cap helps aid in service port sealing and helps protect the refrigerant system from contamination. Remember to always reinstall the protective cap onto the service port when refrigerant system service is complete. 5. Install the protective cap (1) onto the service port. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair Repairs and Inspections Required After a Collision: Service and Repair SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT Any vehicle which is to be returned to use following a Supplemental Restraint System (SRS) component deployment must have the deployed restraints replaced. In addition, if the driver airbag has been deployed, the clockspring must be replaced and the steering column must be inspected. See: Steering and Suspension/Steering/Steering Column/Testing and Inspection. If the passenger airbag is deployed, the passenger airbag door must be replaced. If the knee blocker airbag is deployed, the instrument panel must be replaced. The seat belt tensioners are deployed in conjunction with front airbags, but can also be deployed with seat (thorax) or side curtain airbags. The seat belt tensioners must be replaced if either front airbag has been deployed, and must be inspected if either seat or side curtain airbag has been deployed. If a seat airbag is deployed, the seat back frame, the seat back foam and the seat back trim cover on the same side of the vehicle as the deployed airbag must also be replaced. If a side curtain airbag has been deployed, the headliner as well as the upper A, B, C and D-pillar trim on the same side of the vehicle as the deployed airbag must be replaced. These components are not intended for reuse and will be damaged or weakened as a result of a SRS component deployment, which may or may not be obvious during a visual inspection. On vehicles with an optional sunroof, the sunroof drain tubes and hoses must be closely inspected following a side curtain airbag deployment. It is also critical that the mounting surfaces and mounting brackets for the Occupant Restraint Controller (ORC), side impact sensors and front impact sensors be closely inspected and restored to their original conditions following any vehicle impact damage. Because the ORC and each impact sensor are used by the SRS to monitor or confirm the direction and severity of a vehicle impact, improper orientation or insecure fastening of these components may cause airbags not to deploy when required, or to deploy when not required. There are two methods by which an airbag or seat belt tensioner may be connected to the vehicle electrical system. The first method involves a short pigtail harness and connector insulator that are integral to the airbag or tensioner unit and are replaced as a unit with the service replacement airbag or seat belt tensioner unit. The second method involves a wire harness takeout and connector insulator (squib circuits) that are connected directly to the air bag or tensioner initiator. The heat created by the initiator during an airbag or tensioner deployment will cause collateral damage to a directly connected wire harness take out and connector insulator. Therefore, these direct-connect type take outs and connector insulators must be repaired following an airbag or seat belt tensioner deployment. See: Service and Repair. All other vehicle components should be closely inspected following any SRS component deployment, but are to be replaced only as required by the extent of the visible damage incurred. AIRBAG SQUIB STATUS Multistage airbags with multiple initiators (squibs) must be checked to determine that all squibs were used during the deployment event. The driver and passenger airbags in this vehicle are deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the driver or passenger squib 1 and squib 2 circuits to the two initiators in the airbag inflators. Typically, both initiators are used and all potentially hazardous chemicals are burned during an airbag deployment event. However, it is possible for only one initiator to be used; therefore, it is always necessary to confirm that both initiators have been used in order to avoid the improper handling or disposal of potentially live pyrotechnic or hazardous materials. The following procedure should be performed using a diagnostic scan tool to verify the status of both airbag squibs before either deployed airbag is removed from the vehicle for disposal. CAUTION: Deployed front airbags having two initiators (squibs) in the airbag inflator may or may not have live pyrotechnic material within the inflator. Do not dispose of these airbags unless you are certain of complete deployment. Refer to the Hazardous Substance Control System for information regarding the potentially hazardous properties of the subject component and the proper safe handling procedures. Then dispose of all non-deployed and deployed airbags and seat belt tensioners in a manner consistent with state, provincial, local and federal regulations. 1. Be certain that the diagnostic scan tool contains the latest version of the proper diagnostic software. Connect the scan tool to the 16-way Data Link Connector (DLC). The DLC is located on the driver side lower edge of the instrument panel, outboard of the steering column. 2. Turn the ignition switch to the ON position. 3. Using the scan tool, read and record the active (current) Diagnostic Trouble Code (DTC) data. Using the active DTC information, refer to the Airbag Squib Status table to determine the status of both driver and passenger airbag squibs. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Page 5968 NOTE: If none of the Driver or Passenger Squib 1 or 2 open are active codes, the status of the airbag squibs is unknown. In this case the airbag should be handled and disposed of as if the squibs were both live. CLEANUP PROCEDURE Following a Supplemental Restraint System (SRS) component deployment, the vehicle interior will contain a powdery residue. This residue consists primarily of harmless particulate by-products of the small pyrotechnic charge that initiates the propellant used to deploy a SRS component. However, this residue may also contain traces of sodium hydroxide powder, a chemical by-product of the propellant material that is used to generate the inert gas that inflates the airbag. Since sodium hydroxide powder can irritate the skin, eyes, nose, or throat, be certain to wear safety glasses, rubber gloves, and a long-sleeved shirt during cleanup. WARNING: To avoid serious or fatal injury, if you experience skin irritation during cleanup, run cool water over the affected area. Also, if you experience irritation of the nose or throat, exit the vehicle for fresh air until the irritation ceases. If irritation continues, see a physician. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Page 5969 1. Begin the cleanup by using a vacuum cleaner to remove any residual powder from the vehicle interior. Clean from outside the vehicle and work your way inside, so that you avoid kneeling or sitting on a non-cleaned area. 2. Be certain to vacuum the heater and air conditioning outlets as well. Run the heater and air conditioner blower on the lowest speed setting and vacuum any powder expelled from the outlets. CAUTION: Deployed front airbags having two initiators (squibs) in the airbag inflator may or may not have live pyrotechnic material within the inflator. Do not dispose of these airbags unless you are certain of complete deployment. Refer to the AIRBAG SQUIB STATUS heading within this information. All damaged, ineffective, or non-deployed Supplemental Restraint System (SRS) components which are replaced on vehicles are to be handled and disposed of properly. If an airbag or seat belt tensioner unit is ineffective or damaged and non-deployed, refer to the Hazardous Substance Control System for information regarding the potentially hazardous properties of the subject component and the proper safe handling procedures. Then dispose of all non-deployed and deployed airbags and seat belt tensioners in a manner consistent with state, provincial, local and federal regulations. 3. Next, remove the deployed SRS components from the vehicle. Refer to the appropriate service removal procedures. 4. You may need to vacuum the interior of the vehicle a second time to recover all of the powder. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib Air Bag: Locations Driver Airbag Squib Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib > Page 5975 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib > Page 5976 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib > Page 5977 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib > Page 5978 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib > Page 5979 Air Bag: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib > Page 5980 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib > Page 5981 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib > Page 5982 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib > Page 5983 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib > Page 5984 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib > Page 5985 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Knee Blocker Airbag (Except Base) (Instrument Panel) 2 Way Air Bag: Diagrams Driver Knee Blocker Airbag (Except Base) (Instrument Panel) 2 Way Connector (EXCEPT BASE) - (INSTRUMENT PANEL) 2 WAY AIRBAG-KNEE BLOCKER-DRIVER (EXCEPT BASE) - (INSTRUMENT PANEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Knee Blocker Airbag (Except Base) (Instrument Panel) 2 Way > Page 5988 Air Bag: Diagrams Left Seat Airbag (Left SAB Jumper) 2 Way Connector - (LEFT SAB JUMPER) 2 WAY AIRBAG-SEAT-LEFT - (LEFT SAB JUMPER) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Knee Blocker Airbag (Except Base) (Instrument Panel) 2 Way > Page 5989 Air Bag: Diagrams Passenger Airbag Squib 1 (Except Base) (Instrument Panel) 2 Way Connector (EXCEPT BASE) - (INSTRUMENT PANEL) 2 WAY AIRBAG-PASSENGER SQUIB 1 (EXCEPT BASE) - (INSTRUMENT PANEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Knee Blocker Airbag (Except Base) (Instrument Panel) 2 Way > Page 5990 Air Bag: Diagrams Passenger Airbag Squib 2 (Except Base) (Instrument Panel) 2 Way Connector (EXCEPT BASE) - (INSTRUMENT PANEL) 2 WAY AIRBAG-PASSENGER SQUIB 2 (EXCEPT BASE) - (INSTRUMENT PANEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Knee Blocker Airbag (Except Base) (Instrument Panel) 2 Way > Page 5991 Air Bag: Diagrams Driver Knee Blocker Airbag (Except Base) (Instrument Panel) 2 Way Connector (EXCEPT BASE) - (INSTRUMENT PANEL) 2 WAY AIRBAG-KNEE BLOCKER-DRIVER (EXCEPT BASE) - (INSTRUMENT PANEL) 2 WAY Left Seat Airbag (Left SAB Jumper) 2 Way Connector - (LEFT SAB JUMPER) 2 WAY AIRBAG-SEAT-LEFT - (LEFT SAB JUMPER) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Knee Blocker Airbag (Except Base) (Instrument Panel) 2 Way > Page 5992 Passenger Airbag Squib 1 (Except Base) (Instrument Panel) 2 Way Connector (EXCEPT BASE) - (INSTRUMENT PANEL) 2 WAY AIRBAG-PASSENGER SQUIB 1 (EXCEPT BASE) - (INSTRUMENT PANEL) 2 WAY Passenger Airbag Squib 2 (Except Base) (Instrument Panel) 2 Way Connector (EXCEPT BASE) - (INSTRUMENT PANEL) 2 WAY AIRBAG-PASSENGER SQUIB 2 (EXCEPT BASE) - (INSTRUMENT PANEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Knee Blocker Airbag (Except Base) (Instrument Panel) 2 Way > Page 5993 Driver Airbag Squib 1 (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY AIRBAG-DRIVER SQUIB 1 - (STEERING WHEEL) 2 WAY Driver Airbag Squib 2 (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY AIRBAG-DRIVER SQUIB 2 - (STEERING WHEEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Knee Blocker Airbag (Except Base) (Instrument Panel) 2 Way > Page 5994 Left Side Curtain Airbag (Body) 2 Way Connector - (BODY) 2 WAY AIRBAG-SIDE CURTAIN-LEFT - (BODY) 2 WAY Right Seat Airbag (Right SAB Jumper) 2 Way Connector - (RIGHT SAB JUMPER) 2 WAY AIRBAG-SEAT-RIGHT - (RIGHT SAB JUMPER) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Knee Blocker Airbag (Except Base) (Instrument Panel) 2 Way > Page 5995 Right Side Curtain Airbag (Body) 2 Way Connector - (BODY) 2 WAY AIRBAG-SIDE CURTAIN-RIGHT - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description Air Bag: Description and Operation Side Curtain Air Bag - Description DESCRIPTION Side curtain airbags are available equipment in this vehicle when it is also equipped with dual front airbags. These airbags are passive, inflatable, Supplemental Restraint System (SRS) components, and vehicles with this equipment can be readily identified by a molded identification trim button with the SRS - AIRBAG logo located on the headliner above each B-pillar. This system is designed to reduce injuries to the vehicle occupants in the event of a side impact collision or a vehicle rollover incident. Vehicles equipped with side curtain airbags have two individually controlled curtain airbag units. These airbag units are concealed and mounted above the headliner where they are each secured to one of the roof side rails. Each folded airbag cushion is contained within a fabric wrap and extruded plastic channels that extend along the roof rail from the A-pillar at the front of the vehicle to just forward of the D-pillar at the rear of the vehicle. A long tether (3) extends down the A-pillar from the front of the airbag cushion. The end of the tether is secured to a slot in the sheet metal with a metal clip, while two additional plastic fasteners secure the tether to the inside of the A-pillar. A short tether (4) extends down the D-pillar from the rear of the airbag cushion and is also secured with a metal clip. The hybrid-type inflator (1) for each airbag is secured to the roof rail near the rear of the airbag unit between the C-pillar and the D-pillar, and is connected to the airbag cushion by a long tubular manifold (2). The inflator bracket and the extruded airbag cushion channel are secured with both plastic push-in fasteners and screws to U-nuts installed in the roof rail. The initiator (5) of the airbag inflator is connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness near the top of the D-pillar. The body wire harness connects the airbag unit to the Occupant Restraint Controller (ORC). The side curtain airbag unit cannot be adjusted or repaired and must be replaced if deployed, ineffective, or in any way damaged. Once a side curtain airbag has been deployed, the complete airbag unit, the headliner, the upper A, B, C and D-pillar trim, and all other visibly damaged components must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 5998 Air Bag: Description and Operation Side Curtain Air Bag - Operation OPERATION Each side curtain airbag is deployed individually by an electrical signal generated by the Occupant Restraint Controller (ORC) to which it is connected through left or right curtain airbag line 1 and line 2 (or squib) circuits. The hybrid-type inflator assembly for each airbag contains a small canister of highly compressed inert gas. When the ORC sends the proper electrical signal to the airbag inflator, the electrical energy creates enough heat to ignite chemical pellets within the inflator. Once ignited, these chemicals burn rapidly and produce the pressure necessary to rupture a containment disk in the inert gas canister. The inflator and inert gas canister are sealed and connected to a tubular manifold so that all of the released gas is directed into the folded curtain airbag cushion, causing the cushion to inflate. As the airbag cushion inflates it will drop down from the roof rail between the edge of the headliner and the side glass/body pillars to form a curtain-like cushion to protect the vehicle occupants during a side impact collision or a vehicle rollover incident. The front and rear tethers keep the side curtain bag taut to the side of the vehicle, thus ensuring that the bag will deploy in the proper position. Following the airbag deployment, the airbag cushion slowly deflates by venting the inert gas through the loose weave of the cushion fabric, and the deflated cushion hangs down loosely from the roof rail. Proper diagnosis of the side curtain airbag inflator and squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 5999 Air Bag: Description and Operation Driver Air Bag - Description DESCRIPTION The injection molded, thermoplastic driver airbag protective trim cover (2) is the most visible part of the driver airbag. The driver airbag is located in the center of the steering wheel (1), where it is secured with two screws to the horn switch within the hub cavity of the four-spoke steering wheel. An injection molded, bright emblem with the Dodge Ram logo is applied to the center of the trim cover. Concealed beneath the driver air bag trim cover are the folded airbag cushion, the airbag housing, the airbag inflator and the retainers that secure the inflator to the housing. The airbag cushion, housing (3), and inflator (2) are secured within an integral receptacle molded into the back of the trim cover. The four vertical walls of this receptacle have numerous small windows with blocking tabs that are engaged by numerous hook formations around the perimeter of the airbag housing. Each hook is inserted through one of the windows and the blocking tab in each window keeps the hook properly engaged with the trim cover, locking the trim cover securely into place on the airbag housing. The two mounting tabs (5) extend from the housing to secure the housing to the horn switch. The airbag used in this vehicle is a multistage-type that complies with revised federal airbag standards to deploy with less force than those used in some prior vehicles. A radial deploying 67.3 centimeter (26.5 inch) diameter fabric airbag cushion with internal tethers is used. The airbag inflator is a dual-initiator, non-azide, pyrotechnic-type unit with four mounting studs and is secured to the stamped metal airbag housing using four flanged hex nuts. Two keyed and color-coded connector receptacles (4) on the driver airbag inflator connect the two inflator initiators to the vehicle electrical system through two yellow-jacketed, two-wire pigtail harnesses of the clockspring. The driver airbag cannot be repaired, and must be replaced if deployed, ineffective, or in any way damaged. The driver airbag trim cover may be disassembled from the driver airbag unit, and is available for individual service replacement. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 6000 Air Bag: Description and Operation Driver Air Bag - Operation OPERATION The multistage driver airbag is deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the driver airbag squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two initiators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ORC to suit the monitored impact conditions by providing one of several delay intervals between the electrical signals provided to the two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy. When the ORC sends the proper electrical signals to each initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the back of the airbag housing and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the driver airbag trim cover will split at predetermined breakout lines, then fold back out of the way. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas towards the instrument panel through vent holes within the fabric used to construct the back (steering wheel side) panel of the airbag cushion. Some of the chemicals used to create the inert gas may be considered hazardous while in their solid state before they are burned, but they are securely sealed within the airbag inflator. Typically, both initiators are used and all potentially hazardous chemicals are burned during an airbag deployment event. However, it is possible for only one initiator to be used during a deployment due to an airbag system fault; therefore, it is necessary to always confirm that both initiators have been used in order to avoid the improper disposal of potentially live pyrotechnic or hazardous materials. See: Service and Repair. The inert gas that is produced when the chemicals are burned is harmless. However, a small amount of residue from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noted, rinse the affected area with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician. Proper diagnosis of the driver airbag inflator and squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 6001 Air Bag: Description and Operation Side Curtain Air Bag - Description DESCRIPTION Side curtain airbags are available equipment in this vehicle when it is also equipped with dual front airbags. These airbags are passive, inflatable, Supplemental Restraint System (SRS) components, and vehicles with this equipment can be readily identified by a molded identification trim button with the SRS - AIRBAG logo located on the headliner above each B-pillar. This system is designed to reduce injuries to the vehicle occupants in the event of a side impact collision or a vehicle rollover incident. Vehicles equipped with side curtain airbags have two individually controlled curtain airbag units. These airbag units are concealed and mounted above the headliner where they are each secured to one of the roof side rails. Each folded airbag cushion is contained within a fabric wrap and extruded plastic channels that extend along the roof rail from the A-pillar at the front of the vehicle to just forward of the D-pillar at the rear of the vehicle. A long tether (3) extends down the A-pillar from the front of the airbag cushion. The end of the tether is secured to a slot in the sheet metal with a metal clip, while two additional plastic fasteners secure the tether to the inside of the A-pillar. A short tether (4) extends down the D-pillar from the rear of the airbag cushion and is also secured with a metal clip. The hybrid-type inflator (1) for each airbag is secured to the roof rail near the rear of the airbag unit between the C-pillar and the D-pillar, and is connected to the airbag cushion by a long tubular manifold (2). The inflator bracket and the extruded airbag cushion channel are secured with both plastic push-in fasteners and screws to U-nuts installed in the roof rail. The initiator (5) of the airbag inflator is connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness near the top of the D-pillar. The body wire harness connects the airbag unit to the Occupant Restraint Controller (ORC). The side curtain airbag unit cannot be adjusted or repaired and must be replaced if deployed, ineffective, or in any way damaged. Once a side curtain airbag has been deployed, the complete airbag unit, the headliner, the upper A, B, C and D-pillar trim, and all other visibly damaged components must be Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 6002 replaced. Side Curtain Air Bag - Operation OPERATION Each side curtain airbag is deployed individually by an electrical signal generated by the Occupant Restraint Controller (ORC) to which it is connected through left or right curtain airbag line 1 and line 2 (or squib) circuits. The hybrid-type inflator assembly for each airbag contains a small canister of highly compressed inert gas. When the ORC sends the proper electrical signal to the airbag inflator, the electrical energy creates enough heat to ignite chemical pellets within the inflator. Once ignited, these chemicals burn rapidly and produce the pressure necessary to rupture a containment disk in the inert gas canister. The inflator and inert gas canister are sealed and connected to a tubular manifold so that all of the released gas is directed into the folded curtain airbag cushion, causing the cushion to inflate. As the airbag cushion inflates it will drop down from the roof rail between the edge of the headliner and the side glass/body pillars to form a curtain-like cushion to protect the vehicle occupants during a side impact collision or a vehicle rollover incident. The front and rear tethers keep the side curtain bag taut to the side of the vehicle, thus ensuring that the bag will deploy in the proper position. Following the airbag deployment, the airbag cushion slowly deflates by venting the inert gas through the loose weave of the cushion fabric, and the deflated cushion hangs down loosely from the roof rail. Proper diagnosis of the side curtain airbag inflator and squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Driver Air Bag - Description DESCRIPTION The injection molded, thermoplastic driver airbag protective trim cover (2) is the most visible part of the driver airbag. The driver airbag is located in the center of the steering wheel (1), where it is secured with two screws to the horn switch within the hub cavity of the four-spoke steering wheel. An injection molded, bright emblem with the Dodge Ram logo is applied to the center of the trim cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 6003 Concealed beneath the driver air bag trim cover are the folded airbag cushion, the airbag housing, the airbag inflator and the retainers that secure the inflator to the housing. The airbag cushion, housing (3), and inflator (2) are secured within an integral receptacle molded into the back of the trim cover. The four vertical walls of this receptacle have numerous small windows with blocking tabs that are engaged by numerous hook formations around the perimeter of the airbag housing. Each hook is inserted through one of the windows and the blocking tab in each window keeps the hook properly engaged with the trim cover, locking the trim cover securely into place on the airbag housing. The two mounting tabs (5) extend from the housing to secure the housing to the horn switch. The airbag used in this vehicle is a multistage-type that complies with revised federal airbag standards to deploy with less force than those used in some prior vehicles. A radial deploying 67.3 centimeter (26.5 inch) diameter fabric airbag cushion with internal tethers is used. The airbag inflator is a dual-initiator, non-azide, pyrotechnic-type unit with four mounting studs and is secured to the stamped metal airbag housing using four flanged hex nuts. Two keyed and color-coded connector receptacles (4) on the driver airbag inflator connect the two inflator initiators to the vehicle electrical system through two yellow-jacketed, two-wire pigtail harnesses of the clockspring. The driver airbag cannot be repaired, and must be replaced if deployed, ineffective, or in any way damaged. The driver airbag trim cover may be disassembled from the driver airbag unit, and is available for individual service replacement. Driver Air Bag - Operation OPERATION The multistage driver airbag is deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the driver airbag squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two initiators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ORC to suit the monitored impact conditions by providing one of several delay intervals between the electrical signals provided to the two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy. When the ORC sends the proper electrical signals to each initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the back of the airbag housing and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the driver airbag trim cover will split at predetermined breakout lines, then fold back out of the way. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas towards the instrument panel through vent holes within the fabric used to construct the back (steering wheel side) panel of the airbag cushion. Some of the chemicals used to create the inert gas may be considered hazardous while in their solid state before they are burned, but they are securely sealed within the airbag inflator. Typically, both initiators are used and all potentially hazardous chemicals are burned during an airbag deployment event. However, it is possible for only one initiator to be used during a deployment due to an airbag system fault; therefore, it is necessary to always confirm that both initiators have been used in order to avoid the improper disposal of potentially live pyrotechnic or hazardous materials. See: Service and Repair. The inert gas that is produced when the chemicals are burned is harmless. However, a small amount of residue from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noted, rinse the affected area with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician. Proper diagnosis of the driver airbag inflator and squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Knee Blocker Air Bag - Description Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 6004 DESCRIPTION The injection molded, thermoplastic Inflatable Knee Blocker (IKB) airbag protective trim cover (1) is the most visible part of the knee blocker airbag. The IKB airbag is located below the steering column in the instrument panel steering column opening cover (2) on the driver side of the vehicle. It is secured with two screws to the instrument panel support structure and by multiple integral latch features to the rectangular opening in the steering column opening cover. The IKB trim cover can be readily identified by the SRS AIRBAG text molded into one upper corner. Concealed beneath the IKB trim cover are the folded airbag cushion, the airbag housing, the airbag inflator and the retainer that secures the inflator to the housing. The airbag cushion (2), a stamped steel housing (4), and an inflator initiator (3) are secured within an integral receptacle molded into the back of the trim cover. The upper and lower vertical walls of this receptacle have numerous small windows that are engaged by numerous hook formations (1) on the upper and lower edges of the airbag housing. Each hook is inserted through one of the windows, locking the trim cover securely into place on the airbag housing. The two outer mounting studs extending from the housing secure the airbag to the instrument panel support structure. The center stud secures the airbag cushion retainer and inflator within the housing. The IKB airbag cannot be repaired, and must be replaced if deployed, ineffective, or in any way damaged. The IKB airbag trim cover may be disassembled from the driver airbag unit, and is available for individual service replacement. Following an IKB airbag deployment, the IKB airbag and the instrument panel support structure assembly must be replaced. Knee Blocker Air Bag - Operation OPERATION The Inflatable Knee Blocker (IKB) airbag is deployed by an electrical signal generated by the Occupant Restraint Controller (ORC) through the IKB airbag squib circuit to the initiator in the airbag inflator. When the ORC sends the proper electrical signal to the initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the back of the airbag housing and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the IKB airbag trim cover will split at predetermined breakout lines, then fold down out of the way. Following an airbag deployment, the airbag cushion quickly deflates by venting Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 6005 the inert gas towards the instrument panel through vent holes within the fabric used to construct the back panel of the airbag cushion. Some of the chemicals used to create the inert gas may be considered hazardous while in their solid state before they are burned, but they are securely sealed within the airbag inflator. Typically, all potentially live pyrotechnic or hazardous chemicals are burned during an airbag deployment event. The inert gas that is produced when the chemicals are burned is harmless. However, a small amount of residue from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noted, rinse the affected area with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician. Proper diagnosis of the IKB airbag inflator and squib circuit requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Passenger Air Bag - Description DESCRIPTION The horizontal surface of the injection molded, thermoplastic Passenger Air Bag (PAB) door (1) is the most visible part of the passenger airbag. The PAB door is located above the glove box (2) opening on the top of the instrument panel in front of the front seat passenger seating position. The edges of the PAB door (4) are secured with integral snap features to the instrument panel base trim. Located below the PAB airbag door within the instrument panel is the passenger airbag unit. The PAB unit is secured through two studs (6) on a stamped mounting bracket to the die cast instrument panel structural support armature. The PAB housing (3) fits into a molded receptacle on the back of the PAB door, where several stamped hook formations (5) on the forward and rearward edges of the PAB housing are engaged in mating small window openings on the forward and rearward flanges of the receptacle to secure the PAB door to the PAB housing. These PAB door fasteners and mounting provisions are all concealed beneath the instrument panel base trim. The PAB unit used in this vehicle is a multistage, Next Generation-type that complies with revised federal airbag standards to deploy with less force than those used in some prior vehicles. The PAB unit consists of a stamped and welded metal housing, the airbag cushion, and the airbag inflator (2). The PAB housing contains the airbag inflator and the folded airbag cushion. An approximately 80 centimeter (31.5 inch) wide by 90 centimeter (35.5 inch) high rectangular fabric cushion is used. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 6006 The airbag inflator is a non-azide, pyrotechnic-type unit that is secured to and sealed within the PAB housing. Two inflator initiators (1) are connected to the vehicle electrical system through dedicated take outs and connectors of the instrument panel wire harness. A service replacement PAB does not include the PAB door. The PAB door may be disassembled from the PAB unit and is available for individual service replacement. The PAB unit cannot be repaired and must be replaced if deployed, ineffective, or in any way damaged. Passenger Air Bag - Operation OPERATION The multistage Passenger Air Bag (PAB) is deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the PAB squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two initiators, the PAB can be deployed at multiple levels of force. The force level is controlled by the ORC to suit the monitored impact conditions by providing one of several delay intervals between the electrical signals provided to the two initiators. The longer the delay between these signals, the less forcefully the PAB will deploy. When the ORC sends the proper electrical signals to each initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the airbag cushion and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the PAB door will split at predetermined tear seam lines concealed on the inside surface of the door, then the door will pivot up over the top of the instrument panel and out of the way. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas through a vent hole in each fabric side panel of the airbag cushion. Typically, both initiators are used during an airbag deployment event. However, it is possible for only one initiator to be used during a deployment due to an airbag system fault; therefore, it is necessary to always confirm that both initiators have been used in order to avoid the improper disposal of potentially live pyrotechnic materials. See: Service and Repair. Proper diagnosis of the PAB inflator and the PAB squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Seat Air Bag - Description DESCRIPTION The seat airbags (also known as thorax airbags) are completely concealed beneath the seat back trim cover on the upper outboard sides of both front seat backs. These airbags are inserted into a sewn pouch on the inside of the trim cover, then secured to the seat back frame by nuts on two studs (3). One stud is located on the stamped metal airbag housing (2), while the second stud is located on the stamped metal airbag lower bracket (4). The folded seat airbag cushions are contained within a retainer wrap (1) constructed of the same material as the airbag cushion. The retainer wrap completely encloses the airbag cushion and is engaged over the stud on the housing for retention. The airbag cushion is constructed of a coated nylon fabric. The airbag housing contains the airbag inflator and a heat shield. The airbag inflator is a single-initiator, pyrotechnic-type unit that is secured to and sealed within the airbag housing. The seat airbag is connected to the vehicle electrical system through a dedicated take out of the seat wire harness with a connector insulator that connects directly to the inflator initiator. The connector insulators are uniquely keyed and color-coded to ensure they can only be connected to the initiator. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 6007 The seat airbag cannot be repaired, and must be replaced if deployed, ineffective, or in any way damaged. If the seat airbag is deployed, the seat back frame, the seat back foam cushion, the seat back trim cover and the seat wire harness must also be replaced. Seat Air Bag - Operation OPERATION Each seat airbag is deployed individually by an electrical signal generated by the Occupant Restraint Controller (ORC) to which it is connected through left or right seat airbag line 1 and line 2 (or squib) circuits. The hybrid-type inflator assembly for each airbag contains a small canister of highly compressed inert gas. When the ORC sends the proper electrical signal to the airbag inflator, the electrical energy creates enough heat to ignite chemical pellets within the inflator. Once ignited, these chemicals burn rapidly and produce the pressure necessary to rupture a containment disk in the inert gas canister. The inflator and inert gas canister are sealed and connected so that all of the released gas is directed into the folded seat airbag cushion, causing the cushion to inflate. As the airbag cushion inflates it will split the retainer wrap, the sewn pouch and the outboard side of the seat back trim cover and expand into the area between the outboard side of the front seat and the front door to form a cushion to protect the front seat occupant during a side impact collision or a vehicle rollover incident. Following the airbag deployment, the airbag cushion slowly deflates by venting the inert gas through the loose weave of the cushion fabric, and the deflated cushion hangs down loosely from the outboard side of the front seat back. Proper diagnosis of the seat airbag inflator and squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement Air Bag: Removal and Replacement Side Curtain Air Bag - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the side curtain airbag, or becoming entrapped between the side curtain airbag cushion and the headliner. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged side curtain airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the side curtain airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. See: Service and Repair . 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Lower the headliner from the roof panel. See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Removal. 3. Disconnect the body wire harness connector (2) for the side curtain airbag from the connector receptacle at the back of the inflator (1) on the inner roof side rail between the C and D-pillars. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 6010 4. Disengage the metal clip (1) that secures the side curtain airbag rear tether to the inner roof side rail (5) above the D-pillar. 5. Disengage the metal clip (1) that secures the front tether to the inner A-pillar. 6. Disengage the two plastic fasteners (2) that secure the front tether to the inner A-pillar. 7. Remove the seven screws (6) that secure the side curtain airbag (4) to the U-nuts in the inner roof side rail. 8. Disengage the two plastic push-in fasteners (3) that secure the airbag and the inflator bracket to the inner roof side rail. 9. Remove the side curtain airbag from the vehicle as a unit. Side Curtain Air Bag - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the side curtain airbag, or becoming entrapped between the side curtain airbag cushion and the headliner. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged side curtain airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the side curtain airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. See: Service and Repair . Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 6011 1. Check to be certain that the seven U-nuts (2) for the side curtain airbag are properly installed in the inner roof side rail (1) and that they are in good condition. 2. Position the side curtain airbag (4) into the vehicle as a unit. NOTE: Be certain that the airbag cushion is not twisted during installation. If a colored stripe (red for right side bag, blue for left side bag) is visible on the cushion, the bag is twisted and must be untwisted before it is secured to the roof side rail. 3. Engage the two plastic push-in fasteners (3) that secure the airbag and the inflator bracket to the inner roof side rail (5). 4. Install and tighten the seven screws (6) that secure the side curtain airbag to the U-nuts in the inner roof side rail. Tighten the screws to 5.5 Nm (50 in. lbs.). 5. Engage the two plastic fasteners (2) that secure the side curtain airbag front tether to the inner A-pillar. 6. Engage the metal clip (1) that secures the front tether to the inner A-pillar. 7. Engage the metal clip (1) that secures the rear tether to the inner roof side rail above the D-pillar. 8. Reconnect the body wire harness connector (2) for the side curtain airbag to the connector receptacle at the back of the inflator (1) on the inner roof side rail between the C and D-pillars. 9. Reinstall the headliner into the vehicle. See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Driver Air Bag - Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 6012 WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag cushion and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. NOTE: The following procedure is for replacement of an ineffective or damaged driver airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the driver airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. See: Service and Repair . 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. From the side of the steering wheel (1) hub trim cover, remove the two screws (2) that secure the driver airbag to the horn switch within the hub of the steering wheel. 3. Pull the driver airbag away from the steering wheel (2) far enough to access the electrical connections (3) at the back of the airbag housing (4). CAUTION: Do not pull on the clockspring pigtail wires or pry on the connector insulator to disengage the connector from the driver airbag inflator connector receptacle. Improper removal of these pigtail wires and their connector insulators can result in damage to the airbag circuits or the connector insulators. 4. The clockspring driver airbag pigtail wire connectors are secured by an integral lock to the airbag inflator connector receptacles, which are located on the back of the driver airbag housing. Firmly grasp and pull the lock straight out from the connector insulator, then pull the insulators straight out from the airbag inflator to disconnect them from the connector receptacles. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 6013 5. Remove the driver airbag from the steering wheel. 6. If the driver airbag has been deployed, the clockspring must be replaced and the steering column must be inspected. See: Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement/Clockspring - Removal. See: Steering and Suspension/Steering/Steering Column/Testing and Inspection. Driver Air Bag - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the driver airbag, or becoming entrapped between the driver airbag cushion and the driver airbag trim cover. Failure to observe this warning could result in occupant injuries upon airbag deployment. WARNING: To avoid serious or fatal injury, the driver airbag trim cover must never be painted. Replacement airbags are serviced with trim covers in the original colors. Paint may change the way in which the material of the trim cover responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged driver airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the driver airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. See: Service and Repair . 1. Position the driver airbag (4) close enough to the steering wheel (2) to reconnect the electrical connections (3) on the back of the airbag housing. 2. When installing the driver airbag, reconnect the two clockspring driver airbag pigtail wire connectors to the airbag inflator connector receptacles by pressing straight in on the connectors, then pushing the locks straight into the connectors. Be certain to engage each keyed and color-coded connector to the matching connector receptacle. 3. Carefully position the driver airbag in the steering wheel. Be certain that the clockspring pigtail wires are not pinched between the driver airbag and the horn switch or the steering wheel armature. 4. From the side of the steering wheel hub trim cover, install and tighten the two screws (1) that secure the driver airbag to the horn switch. Tighten the screws to 13 Nm (115 in. lbs.). WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Knee Blocker Air Bag - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 6014 diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag cushion and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. NOTE: The following procedure is for replacement of an ineffective or damaged Inflatable Knee Blocker (IKB) airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the IKB airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. See: Service and Repair . 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the two screws (4) that secure the Inflatable Knee Blocker (IKB) airbag trim cover (5) to the instrument panel support structure. 3. Reach up under and behind the IKB airbag housing (1) and instrument panel support structure (2) to access and remove the two nuts (3) that secure the outer studs of the airbag housing to the instrument panel. It is not necessary to remove the smaller nut from the center stud. This nut secures the airbag cushion retainer and inflator within the airbag housing. If it is removed inadvertently, it is a smaller flanged nut than those on the outer studs allowing it to pass through the center hole of the instrument panel support structure without interference. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the upper and lower edges of the IKB airbag trim cover away from the instrument panel steering column opening cover far enough to disengage the integral latch features on the back of the trim cover from the opening. 5. Pull the IKB airbag rearward far enough to access and disconnect the electrical connection that is secured by integral latches to the airbag inflator initiator connector receptacle on the right end of the airbag housing. Depress the latches on each side of the connector insulator and pull the insulator straight out from the airbag inflator to disconnect it from the connector receptacle. 6. Remove the IKB airbag from vehicle. 7. 7. If the IKB airbag has been deployed, the instrument panel assembly must be replaced. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 6015 Knee Blocker Air Bag - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the Passenger Air Bag (PAB), or becoming entrapped between the PAB cushion and the PAB door. Failure to observe this warning could result in occupant injuries upon airbag deployment. WARNING: To avoid serious or fatal injury, the Passenger Air Bag (PAB) door must never be painted. Replacement PAB doors are serviced in the original colors. Paint may change the way in which the material of the PAB door responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged Inflatable Knee Blocker (IKB) airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the IKB airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. See: Service and Repair . 1. Position the Inflatable Knee Blocker (IKB) airbag and trim cover unit to the opening in the instrument panel steering column opening cover. 2. Reconnect the connector insulator of the instrument panel wire harness IKB airbag take out to the airbag inflator initiator connector receptacle on the right end of the airbag housing by pressing straight in on the connector. You can be certain that the connector is fully engaged in its receptacle by listening carefully for a distinct, audible click as the connector latches snap into place. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 6016 3. Carefully position the IKB airbag housing (1) through the opening in the steering column opening cover far enough to engage the two outboard studs (3) on the airbag housing through the holes in the instrument panel support structure (2). 4. Reach up under and behind the IKB airbag housing and instrument panel support structure to install and tighten the two nuts that secure the outer studs of the airbag housing to the instrument panel. Tighten the nuts to 10.5 Nm (93 in. lbs.). It was not necessary to remove the smaller nut from the center stud. This nut secures the airbag cushion retainer and inflator within the airbag housing. If it was removed inadvertently, it is a smaller flanged nut than those on the outer studs allowing it to pass through the center hole of the instrument panel support structure without interference. 5. Using hand pressure, press on the IKB airbag trim cover over each of the integral latch features on the back of the upper and lower edges of the cover until it engages behind the steering column opening cover. 6. Install and tighten the two screws (4) that secure the IKB airbag trim cover to the instrument panel support structure. Tighten the screws securely. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Passenger Air Bag - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. NOTE: The following procedure is for replacement of an ineffective or damaged Passenger Air Bag (PAB). If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the PAB has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. See: Service and Repair . 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the top cover from the top of the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Removal. 3. Remove the glove box from the instrument panel. See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Removal. CAUTION: Do not pull on the instrument panel wire harness take outs or pry on the connector insulator to disengage the connector from the passenger airbag inflator connector receptacle. Improper removal of these take outs and their connector insulators can result in damage to the airbag circuits or the connector insulators. 4. Reach up into the instrument panel between the upper glove box opening reinforcement and the instrument panel armature (1) to access and disconnect the instrument panel wire harness connectors (2) from the airbag inflator (3). Firmly grasp and pull the lock straight out from the connector insulator, then pull the insulators straight out from the airbag inflator to disconnect them from the connector receptacles. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 6017 5. Remove the two nuts (4) that secure the PAB lower bracket studs to the instrument panel armature. 6. Using a trim stick or another suitable wide flat-bladed tool, gently pry the edges of the PAB door away from the instrument panel far enough to disengage the snap features on the door from the receptacles in the instrument panel base trim. 7. Remove the PAB and PAB door from the top of the instrument panel as a unit. Passenger Air Bag - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the Passenger Air Bag (PAB), or becoming entrapped between the PAB cushion and the PAB door. Failure to observe this warning could result in occupant injuries upon airbag deployment. WARNING: To avoid serious or fatal injury, the Passenger Air Bag (PAB) door must never be painted. Replacement PAB units are serviced with PAB doors in the original colors. Paint may change the way in which the material of the PAB door responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged Passenger Air Bag (PAB). If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the PAB has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. See: Service and Repair . 1. Carefully position the Passenger Air Bag (PAB) and PAB door through the opening in the top of the instrument panel base trim as a unit. Be certain that the two studs of the PAB lower bracket are engaged in the holes of the instrument panel armature (1). 2. Install and tighten the two nuts (4) that secure the PAB lower bracket to the instrument panel armature. Tighten the nuts to 6 Nm (55 in. lbs.). 3. Reconnect the two connector insulators (2) of the instrument panel wire harness PAB take outs to the airbag inflator connector receptacles by pressing straight in on the connectors, then pushing the locks straight into the connectors. Be certain to engage each keyed and color-coded connector to the matching connector receptacle. 4. Using hand pressure, push down on the PAB door over each snap feature on the edges of the door until it snaps into its receptacle in the instrument panel base trim. 5. Reinstall the glove box into the instrument panel. See: Body and Frame/Interior Moulding / Trim/Glove Compartment/Service and Repair/Instrument Panel Glove Box - Installation. 6. Reinstall the top cover onto the top of the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Seat Air Bag - Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 6018 WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. NOTE: The following procedure is for replacement of an ineffective or damaged seat airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the seat airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. See: Service and Repair . 1. Position the front seat to its most forward position for easiest access to the front seat mounting hardware. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the front seat from the vehicle. See: Body and Frame/Seats/Service and Repair/Seat - Removal. CAUTION: During removal of the seat back trim cover, be certain not to tear or damage the integral nylon pouch that contains the seat airbag. If the nylon pouch or the trim cover are torn or damaged, the entire front seat back trim cover must be replaced with a new unit. 4. Remove the trim from the front and back of the front seat back frame (2), but do not remove from the outboard side of the seat back until after the seat airbag has been detached from the seat. See: Body and Frame/Seats/Seat Back/Service and Repair/Overhaul/Seat Back - Disassembly. CAUTION: Do not pull on the seat wire harness (4) take out or pry on the connector insulator to disengage the connector from the seat airbag (1) inflator connector receptacle. Improper removal of this take out and its connector insulator can result in damage to the airbag circuits or the connector insulator. 5. Disconnect the seat wire harness connector from the seat airbag inflator. Slide the yellow locking tab down then squeeze the two latch tabs on the connector insulator. Pull the insulator straight out from the airbag inflator to disconnect it from the connector receptacle. 6. Remove the two nuts (3) that secure the seat airbag to the side of the seat back frame. 7. Grasp the outboard side of the seat back trim cover and pull the trim cover and cushion over the top of the seat back frame. This will allow room to remove the seat airbag without damaging the trim cover or the cushion. 8. Working between the seat back trim cover and the seat back frame carefully disengage the two seat airbag studs from the nylon pouch and slide the airbag out of the pouch. Be careful not to tear or damage the nylon pouch or the trim cover. Seat Air Bag - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 6019 precautions could result in accidental airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged seat airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the seat airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. See: Service and Repair . CAUTION: The seat airbag (1) must be installed into the nylon pouch integral to the front seat back trim cover before the airbag or the trim cover are installed on the front seat back frame (2). Failure to do so will adversely affect the function of the seat airbag system. 1. Carefully slide the seat airbag into the nylon pouch integral to the outboard side of the front seat back trim cover and engage the two airbag studs through the holes provided in the pouch. Be careful not to tear or damage the nylon pouch or the trim cover. 2. Position the seat airbag and trim cover as a unit to the outboard side of the seat back frame (2) and insert the studs through the mounting holes in the frame. 3. Install and tighten the two nuts (3) that secure the seat airbag to the side of the seat back frame. Tighten the nuts to 10 Nm (89 in. lbs.). 4. Reconnect the seat wire harness (4) connector to the seat airbag inflator. Be certain that the connector latches and lock are fully engaged. CAUTION: Be certain that all of the trim is properly reinstalled on the front seat back frame. Failure to do so will adversely affect the function of the seat airbag system. 5. Reinstall the trim onto the front and back of the front seat back (2). See: Body and Frame/Seats/Seat Back/Service and Repair/Overhaul/Seat Back - Assembly. 6. Reinstall the front seat into the vehicle. See: Body and Frame/Seats/Service and Repair/Seat Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 6020 Air Bag: Overhaul Driver Air Bag - Disassembly DISASSEMBLY WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, service of this unit should be performed only by Chrysler-trained and authorized dealer service technicians. Failure to take the proper precautions or to follow the proper procedures could result in accidental, incomplete, or improper airbag deployment and possible occupant injuries. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the driver airbag, or becoming entrapped between the driver airbag cushion and the driver airbag trim cover. Failure to observe this warning could result in occupant injuries upon airbag deployment. WARNING: To avoid serious or fatal injury, the driver airbag trim cover must never be painted. Replacement trim covers are serviced in the original colors. Paint may change the way in which the material of the trim cover responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedures can be used to replace the driver airbag trim cover for service. If the driver airbag is ineffective or deployed, the entire driver airbag and trim cover must be replaced as a unit. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the driver airbag from the steering wheel. See: Removal and Replacement/Driver Air Bag - Removal. 3. Place the driver airbag on a suitable work surface with the trim cover (3) facing down. If the trim cover will be reused, be certain to take the proper precautions to prevent the trim cover from receiving cosmetic damage during the following procedures. 4. Disengage each of the 16 hooks (2) of the airbag housing unit from the 16 windows in the vertical walls of the trim cover, one wall at a time. To disengage the hooks, use hand pressure to push the adjacent edge of the airbag inflator (1) or housing firmly and evenly downward into the trim cover receptacle, while at the same time pulling outward on the upper edge of the receptacle wall. 5. With all of the hooks disengaged, lift the housing, inflator and cushion as a unit from the receptacle on the back of the driver airbag trim cover. Driver Air Bag - Assembly ASSEMBLY WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 6021 WARNING: To avoid serious or fatal injury, service of this unit should be performed only by Chrysler-trained and authorized dealer service technicians. Failure to take the proper precautions or to follow the proper procedures could result in accidental, incomplete, or improper airbag deployment and possible occupant injuries. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the driver airbag, or becoming entrapped between the driver airbag cushion and the driver airbag trim cover. Failure to observe this warning could result in occupant injuries upon airbag deployment. WARNING: To avoid serious or fatal injury, the driver airbag trim cover must never be painted. Replacement trim covers are serviced in the original colors. Paint may change the way in which the material of the trim cover responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedures can be used to replace the driver airbag trim cover for service. If the driver airbag is ineffective or deployed, the entire driver airbag and trim cover must be replaced as a unit. 1. Place the driver airbag trim cover (3) on a suitable work surface with the airbag receptacle facing up. Be certain to take the proper precautions to prevent the trim cover from receiving cosmetic damage during the following procedures. 2. Carefully position the driver airbag housing and inflator unit (1) into the trim cover receptacle. 3. Work around the perimeter of the unit engaging each of the 16 hooks (2) on the driver airbag housing through the 16 windows in the walls of the trim cover receptacle. 4. After the driver airbag has been assembled, try pulling the trim cover and the airbag housing away from each other. This action will fully seat the edges of the trim cover windows into the cradles of the housing hooks. 5. Before reinstalling the airbag onto the steering wheel, check that the blocking tab (1) in each of the trim cover (2) windows is oriented over the airbag housing hook (3) as shown. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 6022 6. Reinstall the driver airbag onto the steering wheel. See: Removal and Replacement/Driver Air Bag - Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Knee Blocker Air Bag - Disassembly DISASSEMBLY WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, service of this unit should be performed only by Chrysler-trained and authorized dealer service technicians. Failure to take the proper precautions or to follow the proper procedures could result in accidental, incomplete, or improper airbag deployment and possible occupant injuries. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the Passenger Air Bag (PAB), or becoming entrapped between the PAB cushion and the PAB door. Failure to observe this warning could result in occupant injuries upon airbag deployment. WARNING: To avoid serious or fatal injury, the Passenger Air Bag (PAB) door must never be painted. Replacement PAB doors are serviced in the original colors. Paint may change the way in which the material of the PAB door responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedures can be used to replace the Inflatable Knee Blocker (IKB) airbag trim cover. If the IKB airbag is deployed, the IKB airbag unit and the trim cover must both be replaced. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the Inflatable Knee Blocker (IKB) airbag and trim cover unit (1) from the instrument panel. See: Removal and Replacement/Knee Blocker Air Bag - Removal. 3. Place the IKB airbag on a suitable work surface with the trim cover facing down. If the trim cover will be reused, be certain to take the proper precautions to prevent the trim cover from receiving cosmetic damage during the following procedures. 4. Disengage each of the 8 hooks (2) on the upper edge of the IKB airbag housing from the 8 windows in the upper vertical wall of the receptacle on the back of the trim cover. To disengage the hooks, use hand pressure to push the edge of the airbag housing firmly and evenly downward into the trim cover receptacle, while at the same time pulling outward on the upper edge of the trim cover receptacle wall. 5. With all of the upper hooks disengaged, rotate the upper edge of the IKB airbag housing (3) toward the lower edge of the trim cover to disengage the 9 hooks (4) on the lower edge of the housing from the 9 windows on the lower wall of the trim cover receptacle. Knee Blocker Air Bag - Assembly ASSEMBLY WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 6023 diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, service of this unit should be performed only by Chrysler-trained and authorized dealer service technicians. Failure to take the proper precautions or to follow the proper procedures could result in accidental, incomplete, or improper airbag deployment and possible occupant injuries. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the Inflatable Knee Blocker (IKB) airbag, or becoming entrapped between the IKB airbag cushion and the IKB airbag trim cover. Failure to observe this warning could result in occupant injuries upon airbag deployment. WARNING: To avoid serious or fatal injury, the Passenger Air Bag (PAB) door must never be painted. Replacement PAB doors are serviced in the original colors. Paint may change the way in which the material of the PAB door responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedures can be used to replace the Inflatable Knee Blocker (IKB) airbag trim cover. If the IKB airbag is deployed, the IKB airbag unit and the trim cover must both be replaced. 1. Place the Inflatable Knee Blocker (IKB) airbag trim cover (1) on a suitable work surface with the airbag receptacle facing up. Be certain to take the proper precautions to prevent the trim cover from receiving cosmetic damage during the following procedures. 2. Carefully align and engage each of the 9 hooks (4) on the lower edge of the IKB airbag housing (3) into the 9 windows in the lower wall of the trim cover receptacle. 3. Rotate the upper edge of the IKB airbag housing upward toward the upper vertical wall of the receptacle on the back of the trim cover. 4. Engage each of the 8 hooks (2) on the upper edge of the IKB airbag housing into the 8 windows in the upper vertical wall of the receptacle on the back of the trim cover. 5. Reinstall the IKB airbag and trim cover unit (1) into the instrument panel. See: Removal and Replacement/Knee Blocker Air Bag - Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Passenger Air Bag - Disassembly DISASSEMBLY WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, service of this unit should be performed only by Chrysler-trained and authorized dealer service technicians. Failure to take the proper precautions or to follow the proper procedures could result in accidental, incomplete, or improper airbag deployment and possible occupant injuries. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the Passenger Air Bag (PAB), or Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 6024 becoming entrapped between the PAB cushion and the PAB door. Failure to observe this warning could result in occupant injuries upon airbag deployment. WARNING: To avoid serious or fatal injury, the Passenger Air Bag (PAB) door must never be painted. Replacement PAB doors are serviced in the original colors. Paint may change the way in which the material of the PAB door responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedures can be used to replace the passenger airbag door. If the passenger airbag is deployed, the passenger airbag unit and the airbag door must both be replaced. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the passenger airbag from the instrument panel. See: Removal and Replacement/Passenger Air Bag - Removal. 3. Place the passenger airbag on a suitable work surface with the passenger airbag door (2) facing down. If the airbag door will be reused, be certain to take the proper precautions to prevent the airbag door from receiving cosmetic damage during the following procedures. 4. Disengage each of the 12 hooks (3) of the airbag housing (1) from the 12 windows in the vertical walls (4) of the receptacle on the underside of the airbag door, one wall at a time. To disengage the hooks, use hand pressure to push the adjacent edge of the airbag housing firmly and evenly downward into the airbag door receptacle, while at the same time pulling outward on the upper edge of the receptacle wall. 5. With all of the hooks disengaged, lift the housing, inflator and cushion from the receptacle on the back of the passenger airbag door. Passenger Air Bag - Assembly ASSEMBLY WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, service of this unit should be performed only by Chrysler-trained and authorized dealer service technicians. Failure to take the proper precautions or to follow the proper procedures could result in accidental, incomplete, or improper airbag deployment and possible occupant injuries. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the Passenger Air Bag (PAB), or becoming entrapped between the PAB cushion and the PAB door. Failure to observe this warning could result in occupant injuries upon airbag deployment. WARNING: To avoid serious or fatal injury, the Passenger Air Bag (PAB) door must never be painted. Replacement PAB doors are serviced in the original colors. Paint may change the way in which the material of the PAB door responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedures can be used to replace the passenger airbag door. If the passenger airbag is deployed, the passenger airbag unit and the airbag door must both be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 6025 1. Place the passenger airbag door (2) on a suitable work surface with the airbag receptacle facing up. Be certain to take the proper precautions to prevent the airbag door from receiving cosmetic damage during the following procedures. 2. Carefully position the passenger airbag housing (1) into the airbag door receptacle. 3. Work around the perimeter of the unit engaging each of the 12 hooks (3) on the passenger airbag housing through the 12 windows in the walls of the airbag door receptacle. 4. After the passenger airbag has been assembled, try pulling the airbag door and the airbag housing away from each other. This action will fully seat the edges of the windows into the cradles of the hooks. 5. Reinstall the passenger airbag onto the instrument panel. See: Removal and Replacement/Passenger Air Bag - Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Occupant Restraint Controller Module C1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Occupant Restraint Controller Module C1 > Page 6030 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 24 Way Air Bag Control Module: Diagrams Occupant Restraint Controller Module C1 (Body) 24 Way Connector - (BODY) 24 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER C1 - (BODY) 24 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 24 Way > Page 6033 Air Bag Control Module: Diagrams Occupant Restraint Controller Module C2 (Body) 32 Way Connector - (BODY) 32 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER C2 - (BODY) 32 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 24 Way > Page 6034 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description Air Bag Control Module: Description and Operation Occupant Restraint Controller - Description DESCRIPTION The Occupant Restraint Controller (ORC) (1) is secured with three nuts to three studs on a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel near the dash panel. The ORC is located beneath the console shifter housing forward of the transmission gearshift mechanism and center floor console in the passenger compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow (2) printed on the label (3) on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges (5) on the left front and rear corners and near the center of the right side. A molded plastic electrical connector receptacle (4) exits the rearward facing side of the ORC housing. This receptacle connects the ORC to the vehicle electrical system through two dedicated take outs and connectors from the instrument panel wire harness. The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with or without side supplemental restraints. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description > Page 6037 Air Bag Control Module: Description and Operation Occupant Restraint Controller - Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC) contains the supplemental restraint system logic circuits and controls all of the Supplemental Restraint System (SRS) components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and for SRS diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ORC microprocessor continuously monitors all of the SRS electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTCs, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. The ORC receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Totally Integrated Power Module (TIPM), and a fused ignition switch output (run-start) circuit through a second fuse in the TIPM. The ORC receives ground through a ground circuit and take out of the instrument panel wire harness. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. Refer to the appropriate wiring information for additional details. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the SRS components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup SRS protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from two remote front impact sensors located on the back of the right and left vertical members of the radiator support near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. On vehicles equipped with optional side curtain airbags or seat airbags, the ORC also monitors inputs from an internal rollover sensor and four additional remote impact sensors located on the left and right inner B-pillars and C-pillars to control deployment of the side curtain airbag and seat airbag units. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a SRS component deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side curtain airbags or seat airbags feature a second safing sensor within the ORC to provide confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require SRS protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either side curtain and seat airbag unit. The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC or the electronic controls or communication between other modules and devices that provide features of the SRS. The most reliable, efficient, and accurate means to diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal Air Bag Control Module: Service and Repair Occupant Restraint Controller - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain or seat airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side curtain and seat airbags in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side curtain and seat airbags will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the SRS components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. NOTE: Several different Occupant Restraint Controllers (ORC) are available for this vehicle. For vehicles equipped with the optional side curtain or seat airbags the ORC contains a second bi-directional safing sensor. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center console shifter bezel and pod from the top of the floor panel transmission tunnel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Removal. 3. Lift, but do not remove, the jute covered panel (1) over the Occupant Restraint Controller (ORC) (2) between the dash panel and the gearshift mechanism as necessary to access the ORC connections and fasteners. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal > Page 6040 4. Remove the three nuts (2) that secure the ORC (3) to the three studs (1) on the ORC mount welded onto the top of the floor panel transmission tunnel (5). 5. Unlatch and disconnect the two instrument panel wire harness connectors (4) from the ORC connector receptacles located on the rearward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm on each connector. 6. Remove the ORC from the ORC mount. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal > Page 6041 Air Bag Control Module: Service and Repair Occupant Restraint Controller - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain or seat airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side curtain and seat airbags in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side curtain and seat airbags will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the SRS components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. NOTE: Several different Occupant Restraint Controllers (ORC) are available for this vehicle. For vehicles equipped with the optional side curtain or seat airbags the ORC contains a second bi-directional safing sensor. 1. Lift, but do not remove, the jute covered panel (1) over the Occupant Restraint Controller (ORC) (2) mount between the dash panel and the gearshift mechanism as necessary to reinstall the ORC, its connections and fasteners. CAUTION: Be certain that the jute covered panel over the ORC is restored to its original installed position following ORC service. Failure to do so may result in the setting of a false Diagnostic Trouble Code (DTC) and illumination of the airbag indicator. This cover protects the ORC from the gearshift selector cables vibrating against or striking the top of the ORC housing, which could be falsely interpreted as a vehicle impact pulse by the sensors within the ORC. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal > Page 6042 2. Carefully position the Occupant Restraint Controller (ORC) (3) onto the three studs (1) of the ORC mount on the floor panel transmission tunnel (5). The bottom of the ORC housing is keyed. When the ORC is correctly positioned, the bottom of the housing will fit flush with the mount and the orientation arrow on the label on top of the housing will be pointed forward in the vehicle. 3. Reconnect the two instrument panel wire harness connectors (4) to the ORC connector receptacles located on the rearward facing side of the module. Be certain that the latches on the connectors are each fully engaged. 4. Install and tighten the three nuts (2) that secure the ORC to the studs of the ORC mount. Tighten the nuts to 9 Nm (80 in. lbs.). 5. Restore the jute covered panel to its proper position over the ORC between the dash panel and the gearshift mechanism. 6. Reinstall the center console shifter pod and bezel onto the top of the floor panel transmission tunnel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Installation. 7. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Clockspring - Description Clockspring Assembly / Spiral Cable: Description and Operation Clockspring - Description DESCRIPTION The clockspring (3) for this vehicle is secured near the top of the steering column below the steering wheel. The clockspring also includes an integral, internal turn signal cancel cam and a Steering Angle Sensor (SAS) that are both serviced as a unit with the clockspring. The clockspring also supports the left (lighting) multi-function switch (1), the Steering Control Module (SCM) internal to the left multi-function switch housing (2), and the right (wiper) multi-function switch (6). Each of these switches and the jumper wire harness (5) between the two multi-function switches can be separated from and are serviced individually from the clockspring. The clockspring case includes integral tabs for mounting the unit with three screws to the steering column lock housing as well as integral provisions for mounting and supporting both multi-function switches. The multi-function switches are each secured to the clockspring with a single screw (7). The SAS within the clockspring includes an electronic circuit board and a microprocessor, which allows it to communicate with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. The SAS circuitry, the clockspring, and the turn signal cancel cam are all contained within a flat, molded plastic case. The clockspring case includes three connector receptacles that face toward the instrument panel. Within the plastic case is a spool-like molded plastic rotor with a large exposed hub. The upper surface of the rotor hub has a large center hole, two short pigtail wires with connectors, and a connector receptacle that faces toward the steering wheel. The lower surface of the rotor has an integral dowel that also faces toward the steering wheel. Wound around the rotor spool within the case is a long ribbon-like tape that consists of several thin copper wire leads sandwiched between two thin plastic membranes. The outer end of the tape terminates at two of the connector receptacles that face the instrument panel, while the inner end of the tape terminates at the pigtail wires and connector receptacle on the hub of the clockspring rotor that face the steering wheel. The outer surface of the rotor hub rim within the clockspring case also has the integral lobes of the turn signal cancel cam. The service replacement clockspring is shipped pre-centered and with a molded plastic locking pin (4) installed. The locking pin secures the centered clockspring rotor to the clockspring case during shipment and handling, but must be removed after the clockspring is installed on the steering column and the steering wheel is installed. See: Service and Repair/Procedures. The clockspring cannot be repaired. If the clockspring is ineffective, damaged, or if the driver airbag has been deployed, the clockspring/turn signal cancel cam/SAS unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Clockspring - Description > Page 6047 Clockspring Assembly / Spiral Cable: Description and Operation Clockspring - Operation OPERATION The clockspring is a mechanical electrical circuit component that is used to provide continuous electrical continuity between the fixed instrument panel wire harness and certain electrical components mounted on or in the rotating steering wheel. On this vehicle the rotating electrical components include the driver airbag, the horn switch, the speed control switch, and the remote radio switches, if the vehicle is so equipped. The clockspring is positioned and secured near the top of the steering column. The fixed connector receptacles on the back of the fixed clockspring case connect the clockspring to the vehicle electrical system through three take outs with connectors from the instrument panel wire harness. The turn signal cancel cam is integral to the rim of the clockspring rotor hub within the clockspring case so it also moves with the rotation of the steering wheel. Two short, black-sleeved pigtail wires on the upper surface of the clockspring rotor connect the clockspring to the driver airbag, while a steering wheel wire harness connected to the connector receptacle on the upper surface of the clockspring rotor complete circuits to the horn switch, the speed control switch and, if the vehicle is so equipped, to the optional remote radio switches on the steering wheel. The third connector receptacle is dedicated to the inputs and outputs of the Steering Angle Sensor (SAS) internal to the clockspring case. Like the clockspring in a timepiece, the clockspring tape has travel limits and can be damaged by being wound too tightly during full stop-to-stop steering wheel rotation. To prevent this from occurring, the clockspring is centered when it is installed on the steering column. Centering the clockspring indexes the clockspring tape to the movable steering components so that the tape can operate within its designed travel limits. However, if the steering wheel is removed from the steering column, if the clockspring is removed from the steering column, or if the steering shaft is disconnected from the steering gear, the clockspring spool can change position relative to the other steering components. The clockspring must be re-centered following completion of this service or the tape may be damaged. Service replacement clocksprings are shipped pre-centered and with a plastic locking pin installed. This locking pin should not be removed until the steering wheel has been installed on the steering column. If the locking pin is removed before the steering wheel is installed on a steering column, the clockspring centering procedure must be performed. See: Service and Repair/Procedures. Proper clockspring installation may be confirmed by viewing the SAS data using a diagnostic scan tool. The hard wired clockspring circuits as well as the hard wired inputs and outputs of the SAS may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SAS or the electronic controls or communication between other modules and devices that provide features of the Electronic Stability Program (ESP) or Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the SAS or the electronic controls and communication related to ESP or SRS operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures Clockspring Assembly / Spiral Cable: Procedures CLOCKSPRING CENTERING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A service replacement clockspring is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin should not be removed until the steering wheel has been installed on the steering column. If the locking pin is removed before the steering wheel is installed, the clockspring centering procedure must be performed. NOTE: When a clockspring is installed into a vehicle without properly centering and locking the entire steering system, the Steering Angle Sensor (SAS) data does not agree with the true position of the steering system and causes the Electronic Stability Program (ESP) system to shut down. This may also damage the clockspring without any immediate malfunction. Unlike some other Chrysler vehicles, this SAS never requires calibration. However, upon each new ignition ON cycle, the steering wheel must be rotated slightly to initialize the SAS. NOTE: Determining if the clockspring/SAS is centered is also possible electrically using the diagnostic scan tool. Steering wheel position is displayed as ANGLE with a range of up to 900 degrees. Refer to the appropriate menu item on the diagnostic scan tool. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position and that the entire steering system is locked or inhibited from rotation. NOTE: The clockspring may be centered and the rotor may be rotated freely once the steering wheel has been removed. 1. Place the front wheels in the straight-ahead position and inhibit the steering column shaft from rotation. 2. Remove the steering wheel from the steering shaft. See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Removal. 3. Rotate the clockspring rotor (1) clockwise to the end of its travel. Do not apply excessive torque. 4. From the end of the clockwise travel, rotate the rotor about two and one-half turns counterclockwise. Turn the rotor slightly clockwise or counterclockwise as necessary so that the clockspring airbag pigtail wires (3) and connector receptacle are at the top and the dowel pin (5) is at the bottom. 5. The clockspring is now centered. Secure the clockspring rotor to the clockspring case using a locking pin (2) or some similar device to maintain clockspring centering until the steering wheel is reinstalled on the steering column. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 6050 Clockspring Assembly / Spiral Cable: Removal and Replacement Clockspring - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A service replacement clockspring is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin should not be removed until the steering wheel has been installed on the steering column. If the locking pin is removed before the steering wheel is installed, the clockspring centering procedure must be performed. NOTE: When a clockspring is installed into a vehicle without properly centering and locking the entire steering system, the Steering Angle Sensor (SAS) data does not agree with the true position of the steering system and causes the Electronic Stability Program (ESP) system to shut down. This may also damage the clockspring without any immediate malfunction. Unlike some other Chrysler vehicles, this SAS never requires calibration. See: Procedures . NOTE: Determining if the clockspring/SAS is centered is also possible electrically using the diagnostic scan tool. Steering wheel position is displayed as ANGLE with a range of up to 900 degrees. Refer to the appropriate menu item on the diagnostic scan tool. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position and that the entire steering system is locked or inhibited from rotation. 1. Place the front wheels in the straight ahead position and inhibit the steering column shaft from rotation. 2. Disconnect and isolate the battery negative cable. 3. Remove the steering wheel from the steering shaft. See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Removal. 4. If the removed clockspring is to be reused, be certain to secure the clockspring rotor to the clockspring case to maintain clockspring centering until the steering wheel is reinstalled on the steering column. If clockspring centering is not maintained, the clockspring must be centered again before the steering wheel is reinstalled. See: Procedures. 5. Move the steering column to the fully lowered position and leave the tilt release lever in the released (down) position. 6. Remove the upper and lower shrouds from the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 7. Remove the right multi-function switch (3) from the clockspring (4). See: Sensors and Switches/Sensors and Switches - Wiper and Washer Systems/Wiper Switch/Service and Repair/Right Multifunction Switch - Removal. 8. Remove the left multi-function switch (5) from the clockspring. See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. 9. Remove the three screws (1) that secure the clockspring to the steering column lock housing (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 6051 10. Pull the clockspring (1) away from the steering column lock housing far enough to access and disconnect the three instrument panel wire harness connectors (2) from the receptacles on the back of the clockspring case. 11. Remove the clockspring from the steering column. Clockspring - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: A service replacement clockspring is shipped with the clockspring pre-centered and with a molded plastic locking pin installed. This locking pin should not be removed until the steering wheel has been installed on the steering column. If the locking pin is removed before the steering wheel is installed, the clockspring centering procedure must be performed. NOTE: When a clockspring is installed into a vehicle without properly centering and locking the entire steering system, the Steering Angle Sensor (SAS) data does not agree with the true position of the steering system and causes the Electronic Stability Program (ESP) system to shut down. This may also damage the clockspring without any immediate malfunction. Unlike some other Chrysler vehicles, this SAS never requires calibration. See: Procedures . NOTE: Determining if the clockspring/SAS is centered is also possible electrically using the diagnostic scan tool. Steering wheel position is displayed as ANGLE with a range of up to 900 degrees. Refer to the appropriate menu item on the diagnostic scan tool. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position and that the entire steering system is locked or inhibited from rotation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 6052 1. If a new clockspring (1) is being installed, transfer the multifunction switch jumper harness from the old clockspring or position a new jumper harness onto the new clockspring. 2. Carefully slide the clockspring down over the steering column upper shaft far enough to reconnect the three instrument panel wire harness connectors (2) to the receptacles on the back of the clockspring case. 3. Position the clockspring (4) onto the steering column lock housing (2). 4. Install and tighten the three screws (1) that secure the clockspring to the lock housing in the following sequence: lower right, upper left, upper right. Tighten the screws to 3 Nm (27 in. lbs.). NOTE: Use of an improper sequence when tightening the clockspring mounting screws may result in an audible ticking noise as the steering wheel is rotated. 5. Reinstall the left multi-function switch (5) onto the clockspring. See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Installation. 6. Reinstall the right multi-function switch (3) onto the clockspring. See: Sensors and Switches/Sensors and Switches - Wiper and Washer Systems/Wiper Switch/Service and Repair/Right Multifunction Switch - Installation. 7. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 8. Move the steering column back to the fully raised position and move the tilt release lever back to the locked (up) position. 9. Reinstall the steering wheel onto the steering column. See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Installation. 10. Remove the plastic locking pin that secures the clockspring rotor to the clockspring case to maintain clockspring centering. 11. Reconnect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6057 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6058 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6059 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6060 Impact Sensor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6061 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6062 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6063 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6064 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6065 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way Impact Sensor: Diagrams Left Front Impact Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-FRONT IMPACT-LEFT - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 6068 Impact Sensor: Diagrams Left Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 1 - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 6069 Impact Sensor: Diagrams Right Front Impact Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-FRONT IMPACT-RIGHT - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 6070 Impact Sensor: Diagrams Right Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-RIGHT 1 - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 6071 Impact Sensor: Diagrams Left Front Impact Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-FRONT IMPACT-LEFT - (ENGINE COMPARTMENT) 2 WAY Left Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 1 - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 6072 Right Front Impact Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-FRONT IMPACT-RIGHT - (ENGINE COMPARTMENT) 2 WAY Right Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-RIGHT 1 - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 6073 Left Side Impact Sensor 2 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-LEFT 2 - (BODY) 2 WAY Right Side Impact Sensor 2 (Body) 2 Way Connector - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 6074 SENSOR-SIDE IMPACT-RIGHT 2 - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description Impact Sensor: Description and Operation Impact Sensor - Description Front FRONT Two front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front sensor is secured with a screw to the backs of the right and left vertical members of the radiator support within the engine compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side SIDE Four side impact sensors (1) are used on this vehicle when it is equipped with the optional side curtain airbags, two each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a screw to the inner right or left B-pillar ahead of the front seat belt retractor, and the inner quarter panel near the C-pillar beneath the trim within the passenger compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 6077 The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 6078 Impact Sensor: Description and Operation Impact Sensor - Operation Front FRONT The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the Supplemental Restraint System (SRS) electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the front impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side SIDE The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side Supplemental Restraint System (SRS) electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through the same left or right sensor plus and minus circuits in a series arrangement from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal Impact Sensor: Service and Repair Impact Sensor - Removal Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. NOTE: The front and side impact sensors are interchangeable. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the screw (4) that secures the impact sensor (3) to the of the right or left radiator support vertical member (2). 3. Disconnect the engine compartment wire harness connector (1) from the right or left front impact sensor connector receptacle. 4. Remove the right or left front impact sensor from the engine compartment. Side - B-Pillar SIDE - B-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and side impact sensors are interchangeable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 6081 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the trim from the inside of the lower right or left B-pillar (3). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. 4. Remove the screw (1) that secures the side impact sensor (2) to the lower B-pillar. 5. Disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the sensor from the B-pillar. Side - C-Pillar SIDE - C-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and side impact sensors are interchangeable. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the quarter trim panel from the inside of the lower C-pillar (1). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Remove the screw (4) that secures the side impact sensor (3) to the C-pillar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 6082 4. Disconnect the body wire harness connector (2) from the sensor (3) connector receptacle. 5. Remove the sensor from the C-pillar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 6083 Impact Sensor: Service and Repair Impact Sensor - Installation Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. NOTE: The front and side impact sensors are interchangeable. 1. Position the right or left front impact sensor (3) into the engine compartment. 2. Reconnect the engine compartment wire harness connector (1) to the sensor connector receptacle. 3. Carefully position the sensor onto the back of the right or left radiator support vertical member (2). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the radiator support. 4. Install and tighten the screw (4) that secures the sensor to the back of the support vertical member. Tighten the screw to 8 Nm (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Side - B-Pillar SIDE - B-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 6084 NOTE: The front and side impact sensors are interchangeable. 1. Reconnect the body wire harness connector (4) to the side impact sensor (2) connector receptacle. 2. Position the sensor onto the inner B-pillar (3). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the B-pillar. 3. Install and tighten the screw (1) that secures the sensor to the inner B-pillar. Tighten the screw to 8 Nm (70 in. lbs.). 4. Reinstall the lower trim onto the inside of the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation. 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Side - C-Pillar SIDE - C-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and side impact sensors are interchangeable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 6085 1. Reconnect the body wire harness connector (2) to the side impact sensor (3) connector receptacle. 2. Position the sensor onto the lower inner C-pillar (1). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the C-pillar. 3. Install and tighten the screw (4) that secures the sensor to the inner C-pillar. Tighten the screw to 8 Nm (70 in. lbs.). 4. Reinstall the quarter trim panel onto the inner lower C-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description Seat Position Sensor: Description and Operation Seat Track Position Sensor - Description DESCRIPTION The seat track position sensor (2) is a Hall Effect-type sensor used on some vehicles. This sensor consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the molded plastic sensor housing. The sensor housing has a mounting slot containing an integral latch feature (1) and slides and latches onto a stamped metal blade-type bracket located on the inboard side of the upper outboard seat adjuster track near the rear of both the passenger and driver front seats. A molded connector receptacle (3) integral to the sensor housing is connected to the vehicle electrical system through a connector and take out of the seat wire harness beneath the front seat cushion frame. The seat track position sensor cannot be adjusted or repaired and, if ineffective or damaged, the entire sensor must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description > Page 6090 Seat Position Sensor: Description and Operation Seat Track Position Sensor - Operation OPERATION The seat track position sensor is designed to provide a seat position data input to the Occupant Restraint Controller (ORC) indicating whether the driver or passenger front seat is in a full forward or a not full forward position. The ORC uses this data as an additional logic input for use in determining the appropriate deployment force to be used when deploying the multistage driver side front airbag. The seat track position sensor receives a nominal five volt supply from the ORC. The sensor communicates the seat position by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic Trouble Code (DTC) for any fault that is detected. The ORC then sends messages over the CAN data bus to control the illumination of the airbag indicator in the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The hard wired circuits between the seat track position sensor and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the seat track position sensor or the electronic controls and communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the seat track position sensor or the electronic controls and communication related to seat track position sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal Seat Position Sensor: Service and Repair Seat Track Position Sensor - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Reach under the front seat cushion to access the seat track position sensor (2) on a bracket located on the outboard side near the rear of the upper outboard seat track (3). 3. Using a small screwdriver, hold the latch feature (4) depressed while sliding the connector end of the sensor off of the bracket. 4. Disconnect the seat wire harness connector (1) from the sensor connector receptacle. 5. Remove the sensor from under the front seat. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal > Page 6093 Seat Position Sensor: Service and Repair Seat Track Position Sensor - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the front seat cushion to reconnect the seat wire harness connector (1) to the seat track position sensor (2) connector receptacle. Be certain that the latch on the connector is fully engaged. 2. Align the open end of the sensor to the slide tab of the sensor bracket located on the outboard side near the rear of the upper outboard seat track (3). 3. Push the sensor firmly onto the bracket until the latch feature (4) snaps into place with an audible click. 4. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Occupant Restraint Controller Module C1 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Occupant Restraint Controller Module C1 > Page 6099 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 24 Way Air Bag Control Module: Diagrams Occupant Restraint Controller Module C1 (Body) 24 Way Connector - (BODY) 24 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER C1 - (BODY) 24 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 24 Way > Page 6102 Air Bag Control Module: Diagrams Occupant Restraint Controller Module C2 (Body) 32 Way Connector - (BODY) 32 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER C2 - (BODY) 32 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 24 Way > Page 6103 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description Air Bag Control Module: Description and Operation Occupant Restraint Controller - Description DESCRIPTION The Occupant Restraint Controller (ORC) (1) is secured with three nuts to three studs on a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel near the dash panel. The ORC is located beneath the console shifter housing forward of the transmission gearshift mechanism and center floor console in the passenger compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow (2) printed on the label (3) on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges (5) on the left front and rear corners and near the center of the right side. A molded plastic electrical connector receptacle (4) exits the rearward facing side of the ORC housing. This receptacle connects the ORC to the vehicle electrical system through two dedicated take outs and connectors from the instrument panel wire harness. The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with or without side supplemental restraints. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description > Page 6106 Air Bag Control Module: Description and Operation Occupant Restraint Controller - Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC) contains the supplemental restraint system logic circuits and controls all of the Supplemental Restraint System (SRS) components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and for SRS diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The ORC microprocessor continuously monitors all of the SRS electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTCs, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. The ORC receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Totally Integrated Power Module (TIPM), and a fused ignition switch output (run-start) circuit through a second fuse in the TIPM. The ORC receives ground through a ground circuit and take out of the instrument panel wire harness. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. Refer to the appropriate wiring information for additional details. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the SRS components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup SRS protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from two remote front impact sensors located on the back of the right and left vertical members of the radiator support near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. On vehicles equipped with optional side curtain airbags or seat airbags, the ORC also monitors inputs from an internal rollover sensor and four additional remote impact sensors located on the left and right inner B-pillars and C-pillars to control deployment of the side curtain airbag and seat airbag units. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a SRS component deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with optional side curtain airbags or seat airbags feature a second safing sensor within the ORC to provide confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require SRS protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either side curtain and seat airbag unit. The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC or the electronic controls or communication between other modules and devices that provide features of the SRS. The most reliable, efficient, and accurate means to diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal Air Bag Control Module: Service and Repair Occupant Restraint Controller - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain or seat airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side curtain and seat airbags in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side curtain and seat airbags will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the SRS components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. NOTE: Several different Occupant Restraint Controllers (ORC) are available for this vehicle. For vehicles equipped with the optional side curtain or seat airbags the ORC contains a second bi-directional safing sensor. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center console shifter bezel and pod from the top of the floor panel transmission tunnel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Removal. 3. Lift, but do not remove, the jute covered panel (1) over the Occupant Restraint Controller (ORC) (2) between the dash panel and the gearshift mechanism as necessary to access the ORC connections and fasteners. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal > Page 6109 4. Remove the three nuts (2) that secure the ORC (3) to the three studs (1) on the ORC mount welded onto the top of the floor panel transmission tunnel (5). 5. Unlatch and disconnect the two instrument panel wire harness connectors (4) from the ORC connector receptacles located on the rearward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm on each connector. 6. Remove the ORC from the ORC mount. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal > Page 6110 Air Bag Control Module: Service and Repair Occupant Restraint Controller - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain or seat airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side curtain and seat airbags in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side curtain and seat airbags will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the SRS components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. NOTE: Several different Occupant Restraint Controllers (ORC) are available for this vehicle. For vehicles equipped with the optional side curtain or seat airbags the ORC contains a second bi-directional safing sensor. 1. Lift, but do not remove, the jute covered panel (1) over the Occupant Restraint Controller (ORC) (2) mount between the dash panel and the gearshift mechanism as necessary to reinstall the ORC, its connections and fasteners. CAUTION: Be certain that the jute covered panel over the ORC is restored to its original installed position following ORC service. Failure to do so may result in the setting of a false Diagnostic Trouble Code (DTC) and illumination of the airbag indicator. This cover protects the ORC from the gearshift selector cables vibrating against or striking the top of the ORC housing, which could be falsely interpreted as a vehicle impact pulse by the sensors within the ORC. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal > Page 6111 2. Carefully position the Occupant Restraint Controller (ORC) (3) onto the three studs (1) of the ORC mount on the floor panel transmission tunnel (5). The bottom of the ORC housing is keyed. When the ORC is correctly positioned, the bottom of the housing will fit flush with the mount and the orientation arrow on the label on top of the housing will be pointed forward in the vehicle. 3. Reconnect the two instrument panel wire harness connectors (4) to the ORC connector receptacles located on the rearward facing side of the module. Be certain that the latches on the connectors are each fully engaged. 4. Install and tighten the three nuts (2) that secure the ORC to the studs of the ORC mount. Tighten the nuts to 9 Nm (80 in. lbs.). 5. Restore the jute covered panel to its proper position over the ORC between the dash panel and the gearshift mechanism. 6. Reinstall the center console shifter pod and bezel onto the top of the floor panel transmission tunnel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Shifter Bezel - Installation. 7. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Child Seat Anchor - Description Child Seat Tether Attachment: Description and Operation Child Seat Anchor - Description DESCRIPTION This vehicle is equipped with a Lower Anchors and Tether for Children, or LATCH child restraint anchorage system. The second row seats in these vehicles are equipped with a fixed-position child restraint upper tether anchor for both the center and the two outboard seating positions, and child restraint lower anchors for the two outboard seating positions. The upper tether anchors (1) are each integral to the second row seat back panels. These anchors are each constructed from short lengths of heavy-gauge steel wire that is securely welded into stamped steel cups that are integral to the seat back panels. There is a separate molded plastic trim bezel (2) located around each of these anchors. The child restraint upper tether anchors cannot be adjusted or repaired and, if ineffective or damaged, they must be replaced as a unit with their respective second row seat back panels. The right outboard and both left lower anchors (2) are integral to the second row seat back hinges, which are secured to the rear floor panel at the rear with studs and nuts, and at the front with screws. The right inboard lower anchor is integral to a separate child anchor bracket that is secured to the rear floor panel at the rear with a stud and a nut, and at the front along with the right and center anchor seat belt buckles with a screw. These anchors are each constructed from a heavy-gauge steel wire loop that is securely welded to the hinge or child anchor brackets. The anchor loops are located where the second row seat back (1) meets the seat cushion (3). The child restraint lower tether anchors cannot be adjusted or repaired and, if ineffective or damaged, they must be replaced as a unit with their respective second row seat hinge or child anchor brackets. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Child Seat Anchor - Description > Page 6118 Child Seat Tether Attachment: Description and Operation Child Seat Anchor - Operation OPERATION All vehicles manufactured for sale in the United States and Canada are required to be equipped with a Lower Anchors and Tether for Children, or LATCH child restraint anchorage system. The second row seats in this vehicle have two pairs of anchor provisions for installing a LATCH-compatible child seat. A single seat may be mounted in the center seating position, or one in each outboard seating position. With LATCH, child seats are secured by direct attachment to the vehicle seat structure, rather than by the seat belts. With LATCH-compatible child seats, lower anchors attach to the seat structure through heavy-gauge wire loops located at the intersection between the seat cushion and the seat back surfaces. Three upper tether anchors are integral to the second row seat back frames to secure the top tether strap of child seats equipped with this feature. These upper tether anchors work with both LATCH-compatible and other child seats equipped with a top tether strap. The owner's information packet in the vehicle glove box contains details and suggestions on the proper use of all of the factory-installed child restraint anchors. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Seat Anchor - Removal Child Seat Tether Attachment: Service and Repair Child Seat Anchor - Removal REMOVAL WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. NOTE: The following procedure is for servicing the second row right inboard child restraint lower anchor and bracket. The second row right outboard and both left lower anchors are integral to their respective seat back hinge brackets. See: Body and Frame/Seats/Seat Back/Service and Repair/Overhaul/Seat Back - Disassembly . 1. Remove the second row right and center anchor buckle unit (2) from the rear floor panel (1). See: Seat Belt Buckle/Service and Repair/Seat Belt Buckle - Removal. 2. Remove the nut (4) from the stud (6) that secures the rear of the child anchor bracket (5) to the rear floor panel. 3. Disengage the child anchor bracket from the stud and remove the bracket from under the second row seat back. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Child Seat Anchor - Removal > Page 6121 Child Seat Tether Attachment: Service and Repair Child Seat Anchor - Installation INSTALLATION WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. NOTE: The following procedure is for servicing the second row right inboard child restraint lower anchor and bracket. The second row right outboard and both left lower anchors are integral to their respective seat back hinge brackets. See: Body and Frame/Seats/Seat Back/Service and Repair/Overhaul/Seat Back - Assembly . 1. Position the child anchor bracket (5) under the second row seat back and engage it over the stud (6) on the rear floor panel (1). 2. Install and tighten the nut that secures the bracket to the stud. Tighten the nut to 80 Nm (59 ft. lbs.). 3. Reinstall the second row right and center anchor buckle unit (2) onto the rear floor panel. See: Seat Belt Buckle/Service and Repair/Seat Belt Buckle - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal Seat Belt Buckle: Service and Repair Seat Belt Buckle - Removal Front FRONT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. 1. Move the front seat to its most rearward position for easiest access to the front seat belt buckle (1) lower anchor. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the console from the floor panel transmission tunnel. 4. Remove the screw (2) that secures the front seat belt buckle lower anchor to the inboard side of the front seat cushion frame. 5. Remove the seat belt buckle from the front seat cushion frame. Second Row - Center and Left SECOND ROW - CENTER AND LEFT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 6126 1. Remove the second row seat cushion from the rear floor panel (3). See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 2. Remove the screw (1) that secures the center and left seat belt buckle unit (4) anchor plate and the left center seat back (2) hinge bracket to the rear floor panel. 3. Remove the buckle unit from the rear floor panel. Second Row - Right and Center Anchor SECOND ROW - RIGHT AND CENTER ANCHOR WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. 1. Remove the second row seat cushion from the rear floor panel (1). See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 2. Remove the screw (3) that secures the right and center anchor seat belt buckle unit (2) anchor plate and the child anchor bracket (5) to the rear floor panel. 3. Remove the buckle unit from the rear floor panel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 6127 Seat Belt Buckle: Service and Repair Seat Belt Buckle - Installation Front FRONT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. 1. Position the front seat belt buckle (1) lower anchor onto the inboard side of the seat cushion frame. 2. Install and tighten the screw (2) that secures the front seat belt buckle lower anchor to the seat cushion frame. Tighten the screw to 45 Nm (33 ft. lbs.). 3. Reinstall the console onto the floor panel transmission tunnel. 4. Reconnect the battery negative cable. Second Row - Center and Left SECOND ROW - CENTER AND LEFT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 6128 1. Position the center and left seat belt buckle unit (4) anchor plate onto the left seat back (2) hinge bracket on the rear floor panel (3). 2. Install and tighten the screw (1) that secures the anchor plate and buckles and the left center seat back hinge bracket to the rear floor panel. Tighten the screw to 58 Nm (43 ft. lbs.). 3. Reinstall the second row seat cushion onto the rear floor panel. See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Cushion Cover Installation. Second Row - Right and Center Anchor SECOND ROW - RIGHT AND CENTER ANCHOR WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. 1. Position the right and center anchor seat belt buckle unit (2) anchor plate onto the child anchor bracket (5) on the rear floor panel (1). 2. Install and tighten the screw (3) that secures the buckle unit to the rear floor panel. Tighten the screw to 58 Nm (43 ft. lbs.). 3. Reinstall the second row seat cushion onto the rear floor panel. See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Cushion Cover Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6132 Seat Belt Buckle Switch: Diagrams Connector - (BODY) 2 WAY SWITCH-SEAT BELT-DRIVER - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Seat Belt Switch - Description Seat Belt Buckle Switch: Description and Operation Seat Belt Switch - Description DESCRIPTION The seat belt switch (4) is a small, normally open, single pole, single throw, plunger (3) actuated, momentary switch. One seat belt switch is installed on the driver side front seat belt retractor frame (2) over the retractor spool (1). The seat belt switch includes an integral connector that is connected to the vehicle electrical system through a take out and connector of the body wire harness. The seat belt switch cannot be adjusted or repaired and, if ineffective or damaged, the switch unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Seat Belt Switch - Description > Page 6135 Seat Belt Buckle Switch: Description and Operation Seat Belt Switch - Operation OPERATION The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The seat belt switch plunger is actuated by the seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half, the switch plunger is extended and closes the seat belt switch sense circuit to ground. Conversely, when the seat belt tip-half webbing is wound onto the retractor spool the switch plunger is depressed, opening the ground path. The EMIC monitors the seat belt switch status, then controls the illumination of the seatbelt indicator and the generation of audible electronic chime tones based upon that input. The seat belt switch receives ground through its connection to the body wire harness from another take out of the body wire harness. An eyelet terminal connector on that ground take out is secured under a ground screw. The seat belt switch is connected in series between ground and the seat belt switch sense input of the EMIC. The seat belt switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Service and Repair > Seat Belt Switch - Removal Seat Belt Buckle Switch: Service and Repair Seat Belt Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt switch unit. The front retractor also includes a seat belt tensioner. If the front seat belt switch is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. See: Service and Repair . 1. Adjust the front seat to its most forward position for easiest access to the front seat belt lower anchor cover (1) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the driver side seat belt retractor from the lower B-pillar. See: Seat Belt Retractor/Service and Repair/Seat Belt Retractor - Removal. 4. Extract the seat belt webbing (1) from the retractor far enough to eliminate any contact between the seat belt switch plunger (5) and the webbing on the retractor spool. 5. Lift the latch tab (2) integral to the seat belt switch (4) far enough to allow the switch to be pushed off of the retractor frame tie bar (3). 6. Remove the seat belt switch from the retractor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Service and Repair > Seat Belt Switch - Removal > Page 6138 Seat Belt Buckle Switch: Service and Repair Seat Belt Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt switch unit. The front retractor also includes a seat belt tensioner. If the front seat belt switch is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. See: Service and Repair . 1. Extract the seat belt webbing (1) from the retractor far enough to allow clearance between the seat belt switch plunger (5) and the webbing on the retractor spool during switch installation. 2. Position the seat belt switch (4) to the lower edge of the retractor frame tie bar (3) with the plunger oriented toward the retractor spool. 3. Push the switch onto the tie bar until the integral latch feature (2) is fully engaged over the tie bar. 4. Reinstall the driver side seat belt retractor onto the lower B-pillar. See: Seat Belt Retractor/Service and Repair/Seat Belt Retractor - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Seat Belt Turning Loop Adjuster - Removal Seat Belt Height Adjuster: Service and Repair Seat Belt Turning Loop Adjuster - Removal REMOVAL WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. 1. Firmly grasp the lower end of the turning loop trim cover (2) on the upper B-pillar and pull it straight out to unsnap it from over the height adjuster knob (1), then roll the bottom of the cover upward and pull outward to disengage the upper tab from the slot in the adjuster cover above the knob. 2. Remove the screw (3) that secures the seat belt turning loop to the height adjuster (1). 3. Remove the seat belt turning loop from the height adjuster. 4. Remove the upper trim (2) from the inside of the B-pillar (6). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. 5. Remove the cover (4) from over the height adjuster. 6. Remove the two screws (5) that secure the height adjuster to the inside of the B-pillar. 7. Remove the adjuster from the B-pillar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Seat Belt Turning Loop Adjuster - Removal > Page 6143 Seat Belt Height Adjuster: Service and Repair Seat Belt Turning Loop Adjuster - Installation INSTALLATION WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. 1. Position the seat belt turning loop adjuster (1) to the inside of the B-pillar (6). 2. Install and tighten the two screws (5) that secure the adjuster to the B-pillar. Tighten the screws to 40 Nm (30 ft. lbs.). 3. Position the cover (4) over the height adjuster knob. 4. Reinstall the upper trim (2) onto the inside of the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation. 5. Position the seat belt turning loop onto the height adjuster on the upper B-pillar. Be certain that the seat belt webbing between the retractor and the turning loop is not twisted. 6. Install and tighten the screw (3) that secures the turning loop to the height adjuster. Tighten the screw to 40 Nm (30 ft. lbs.). 7. Insert the upper tab of the turning loop trim cover (2) into the slot in the height adjuster cover above the knob on the upper B-pillar, then roll the bottom of the cover down over the turning loop and use hand pressure to press firmly and evenly on the cover until it snaps into place. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Testing and Inspection Seat Belt Reminder Lamp: Testing and Inspection ENHANCED SEATBELT REMINDER PROGRAMMING The seatbelt indicator also includes a programmable enhanced seatbelt reminder or "belt-minder" feature that is enabled when the vehicle is shipped from the factory. This belt-minder feature provides extended and modified visual seatbelt indicator and audible chime warning responses to an unbuckled driver side or both driver and passenger front seat belts. The belt-minder feature may be disabled or enabled by the customer using the programming sequence that follows, or by the dealer using a diagnostic scan tool. CUSTOMER PROGRAMMING SEQUENCE NOTE: The following sequence of events must occur within sixty (60) seconds of the ignition switch being placed in the On position in order for the programming to be completed successfully. Even if the vehicle is equipped with both driver and passenger side front seat belt switches, this programming sequence MUST be performed using the driver side front seat belt. The passenger side front seat belt switch has no programming functionality. 1. With all doors closed and the ignition switch in any position except On or Start, buckle the driver side front seat belt. 2. Turn the ignition switch to the On position and wait for the seatbelt indicator reminder function to conclude (about six seconds). 3. Unbuckle and buckle the driver side front seat belt three or more times, ending with the belt buckled. NOTE: The occupant must be sure to fully retract the seatbelt each time during this cycle because the actual switch is located in the seatbelt retractor and not the buckle. Each time the seatbelt is buckled or unbuckled, and fully retracted, the seatbelt indicator will illuminate or turn OFF, depending on switch state. 4. Turn the ignition switch to any position except On or Start to toggle the belt-minder feature from its current setting (from active to inactive, or from inactive to active). A single chime tone will provide an audible confirmation that the programming sequence has been successfully completed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation > Seat Belt Retractor - Description Seat Belt Retractor: Description and Operation Seat Belt Retractor - Description DESCRIPTION The seat belt retractors used in all seating positions include an inertia-type, emergency locking mechanism as standard equipment. However, the retractor locking mechanisms for all seating positions except for the driver side front are mechanically switchable from an emergency locking retractor to an automatic locking retractor. The primary function of this feature is to securely accommodate a child seat in any of these seating positions of the vehicle without the need for a self-cinching seat belt tip half latch plate unit or another supplemental device that would be required to prevent the seat belt webbing from unwinding freely from the retractor spool of an inertia-type emergency locking retractor mechanism. The automatic locking mechanism is integral to the seat belt and retractor unit and is concealed beneath a molded plastic cover located on one side of the retractor spool. The automatic locking mechanism cannot be adjusted or repaired and, if ineffective or damaged, the entire seat belt and retractor unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation > Seat Belt Retractor - Description > Page 6151 Seat Belt Retractor: Description and Operation Seat Belt Retractor - Operation OPERATION The locked mode of the automatic locking retractor is engaged and the retractor is switched from operating as a standard inertia-type emergency locking retractor by first buckling the combination lap and shoulder belt buckle. Then grasp the shoulder belt and pull all of the webbing out of the retractor. Once all of the belt webbing is extracted from the spool, the retractor will automatically become engaged in the pre-locked automatic locking mode and will make a light, audible clicking or ratcheting sound as the shoulder belt is allowed to retract to confirm that the automatic locking mode is now engaged. Once the automatic locking mode is engaged, the retractor will remain locked and the belt will remain tight around whatever it is restraining. The retractor is returned to standard emergency locking (inertia) mode by unbuckling the combination lap and shoulder belt buckle and allowing the belt webbing to be almost fully retracted onto the retractor spool. The emergency locking mode is confirmed by the absence of the light, audible clicking or ratcheting sound as the belt webbing retracts. This mode will allow the belt to unwind from and wind onto the retractor spool freely unless and until a predetermined inertia load is sensed, or until the retractor is again switched to the automatic locking mode. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal Seat Belt Retractor: Service and Repair Seat Belt Retractor - Removal Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. See: Service and Repair . NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. See: Description and Operation/Seat Belt Retractor - Description . 1. Adjust the front seat to its most forward position for easiest access to the front seat belt lower anchor cover (1) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. 3. Grasp the upper edge of the lower anchor cover and pull upward to unsnap it from the front seat cushion outboard side shield (4). 4. Remove the screw (2) that secures the seat belt (3) lower anchor to the outboard side of the front seat cushion frame. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 6154 5. Firmly grasp the lower end of the turning loop trim cover (2) on the upper B-pillar and pull it straight out to unsnap it from over the height adjuster knob (1), then roll the bottom of the cover upward and pull outward to disengage the upper tab from the slot in the adjuster cover above the knob. 6. Remove the screw (4) that secures the seat belt turning loop to the height adjuster (2) on the upper B-pillar (1). 7. Remove the seat belt turning loop from the height adjuster. 8. Remove the trim (3) from the lower B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. 9. Pull the front seat belt turning loop and lower anchor through the seat belt opening in the lower B-pillar trim. 10. Disengage the two clips that secure the belt web guide (5) to the B-pillar. 11. Remove the screw (6) that secures the retractor lower bracket to the base of the inner B-pillar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 6155 12. Pull the retractor (1) away from the B-pillar far enough to access and disconnect the yellow body wire harness connector (2) from the seat belt tensioner initiator on the retractor. 13. On the driver side only, disconnect the body wire harness connector (3) from the connector receptacle for the seat belt switch located near the bottom of the retractor. 14. Remove the front seat belt and retractor from the vehicle as a unit. Second Row - Center SECOND ROW - CENTER WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. See: Description and Operation/Seat Belt Retractor - Description . 1. If the second row center seat belt lower anchor (1) is connected, access and unbuckle the lower anchor latch plate from the unique, keyed lower anchor buckle (2). Use an ignition key or a small screwdriver to depress the small latch release button on the anchor buckle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 6156 2. Remove the upper trim (4) from the inside of the right D-pillar. 3. Pull the second row center seat belt latch plate and lower anchor (5) through the seat belt opening in the right upper D-pillar trim. 4. Remove the screw (1) that secures the seat belt turning loop to the right upper D-pillar. 5. Remove the screw (3) that secures the retractor (2) lower bracket to the right quarter inner panel. 6. Remove the second row center seat belt and retractor unit from the right quarter inner panel. Second Row - Outboard SECOND ROW - OUTBOARD WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. See: Description and Operation/Seat Belt Retractor - Description . 1. Remove the rear seat cushion from the vehicle. See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 2. Remove the screw (4) that secures the second row outboard seat belt lower anchor to the rear floor panel (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 6157 3. Remove the upper trim (2) from the inside of the C-pillar (6). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/C-Pillar Trim Panel-Removal. 4. Pull the seat belt lower anchor through the seat belt opening in the upper C-pillar trim. 5. Remove the screw (1) that secures the seat belt turning loop to the upper C-pillar. 6. Remove the seat belt turning loop from the upper C-pillar. 7. Move the trim from the front of the quarter inner panel far enough to access the seat belt retractor (7). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 8. Remove the screw (4) that secures the retractor (1) to the lower C-pillar. 9. Remove the second row outboard seat belt and retractor from the lower C-pillar as a unit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 6158 Seat Belt Retractor: Service and Repair Seat Belt Retractor - Installation Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. See: Service and Repair . NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. See: Description and Operation/Seat Belt Retractor - Description . 1. Position the seat belt and retractor (1) into the vehicle as a unit. 2. On the driver side only, reconnect the body wire harness connector (3) to the connector receptacle for the seat belt switch located near the bottom of the retractor. 3. Reconnect the yellow body wire harness connector (2) to the seat belt tensioner initiator on the retractor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 6159 4. Angle the top of the retractor into the opening in the lower inner B-pillar (1) then roll the lower end of the retractor into the opening. 5. Install and tighten the screw (6) that secures the retractor lower bracket to the base of the inner B-pillar. Tighten the screw to 40 Nm (30 ft. lbs.). 6. Position the belt web guide (5) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 7. Route the front seat belt turning loop and lower anchor through the seat belt opening in the lower B-pillar trim (3). 8. Reinstall the lower trim onto the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation. 9. Position the seat belt turning loop onto the height adjuster (2) on the upper B-pillar. Be certain that the seat belt webbing between the retractor and the turning loop is not twisted. 10. Install and tighten the screw (4) that secures the turning loop to the height adjuster. Tighten the screw to 40 Nm (30 ft. lbs.). 11. Insert the upper tab of the turning loop trim cover (2) into the slot in the height adjuster cover above the knob on the upper B-pillar, then roll the bottom of the cover down over the turning loop and use hand pressure to press firmly and evenly on the cover until it snaps into place. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 6160 12. Position the seat belt (3) lower anchor to the mounting hole on the outboard side of the front seat cushion frame. Be certain that the seat belt webbing between the turning loop and the lower anchor is not twisted. 13. Install and tighten the screw (2) that secures the lower anchor to the seat. Tighten the screw to 40 Nm (30 ft. lbs.). 14. Reinstall the lower anchor cover (1) onto the front seat cushion outboard side shield (4). 15. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Second Row - Center SECOND ROW - CENTER WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. See: Description and Operation/Seat Belt Retractor - Description . 1. Position the second row center seat belt and retractor unit (2) onto the right quarter inner panel. 2. Install and tighten the screw (3) that secures the retractor lower bracket to the right quarter inner panel. Tighten the screw to 40 Nm (30 ft. lbs.). 3. Position the seat belt turning loop to the upper D-pillar. Be certain the seat belt webbing between the retractor and the turning loop is not twisted. 4. Install and tighten the screw (1) that secures the seat belt turning loop to the upper D-pillar. Tighten the screw to 40 Nm (30 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 6161 5. Route the second row center seat belt latch plate and lower anchor (5) through the seat belt opening in the upper D-pillar trim (4). 6. Reinstall the upper trim onto the inside of the right D-pillar. 7. Access and buckle the second row center seat belt lower anchor latch plate (1) to the unique, keyed lower anchor buckle (2). Second Row - Outboard SECOND ROW - OUTBOARD WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. NOTE: All seat belt retractors except the driver side front retractor include a switchable automatic locking mechanism. See: Description and Operation/Seat Belt Retractor - Description . 1. Position the second row seat belt and retractor (7) to the lower inner C-pillar (6). 2. Engage the locator tab on the back of the retractor into the slot in the lower C-pillar. 3. Install and tighten the screw (5) that secures the retractor to the lower C-pillar. Tighten the screw to 40 Nm (30 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 6162 4. Position the seat belt turning loop to the upper C-pillar. Be certain the seat belt webbing between the retractor and the turning loop is not twisted. 5. Install and tighten the screw (1) that secures the turning loop to the upper C-pillar. Tighten the screw to 40 Nm (30 ft. lbs.). 6. Reinstall the trim onto the front of the quarter inner panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 7. Route the seat belt lower anchor through the seat belt opening in the upper C-pillar trim (2). 8. Reinstall the upper trim onto the inside of the C-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/C-Pillar Trim Panel-Installation. 9. Position the seat belt lower anchor to the rear floor panel (3). Be certain the seat belt webbing between the turning loop and the lower anchor is not twisted. 10. Install and tighten the screw (4) that secures the lower anchor to the rear floor panel. Tighten the screw to 58 Nm (43 ft. lbs.). 11. Reinstall the rear seat cushion into the vehicle. See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Driver Seat Belt Tensioner Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Driver Seat Belt Tensioner > Page 6167 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Seat Belt Tensioner (Body) 2 Way Seat Belt Tensioner: Diagrams Driver Seat Belt Tensioner (Body) 2 Way Connector - (BODY) 2 WAY SEAT BELT-TENSIONER-DRIVER - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Seat Belt Tensioner (Body) 2 Way > Page 6170 Seat Belt Tensioner: Diagrams Passenger Seat Belt Tensioner (Body) 2 Way Connector - (BODY) 2 WAY SEAT BELT-TENSIONER-PASSENGER - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Seat Belt Tensioner - Description Seat Belt Tensioner: Description and Operation Seat Belt Tensioner - Description DESCRIPTION Seat belt tensioners supplement the dual front airbags for this vehicle. The seat belt tensioners are integral to the front seat belt retractor units (4), which are secured to the inner B-pillar on the right and left sides of the vehicle. The retractor is concealed beneath the molded plastic inner B-pillar trim. The seat belt tensioner consists primarily of a sprocket/pinion, a steel tube (3), a cast metal housing, numerous steel balls, a stamped metal ball trap (2), a torsion bar and a small pyrotechnically activated gas generator with a connector receptacle (1). All of these components are located on one side of the retractor spool on the outside of the retractor housing except for the torsion bar, which serves as the spindle upon which the retractor spool rides. The seat belt tensioners are controlled by the Occupant Restraint Controller (ORC) and are connected to the vehicle electrical system through a dedicated take out of the body wire harness by a keyed and latching yellow molded plastic connector insulator to ensure a secure connection. The seat belt tensioners cannot be repaired and, if ineffective or damaged, the entire front seat belt and retractor unit must be replaced. If the front airbags have been deployed, the seat belt tensioners have also been deployed. The seat belt tensioners are not intended for reuse and must be replaced following any front airbag deployment. A growling or grinding sound while attempting to operate the seat belt retractor is a sure indication that the seat belt tensioner has been deployed and requires replacement. See: Seat Belt Retractor/Service and Repair/Seat Belt Retractor Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Seat Belt Tensioner - Description > Page 6173 Seat Belt Tensioner: Description and Operation Seat Belt Tensioner - Operation OPERATION The seat belt tensioners are deployed in conjunction with the dual front airbags by a signal generated by the Occupant Restraint Controller (ORC) through the driver or passenger seat belt tensioner line 1 and line 2 (or squib) circuits. When the ORC sends the proper electrical signal to the tensioners, the electrical energy generates enough heat to initiate a small pyrotechnic gas generator. The gas generator is installed in one end of a steel tube that contains numerous steel balls. As the gas expands, it pushes the steel balls through the tube into a cast metal housing, where a ball guide directs the balls into engagement with the teeth of a sprocket that is geared to one end of the retractor spool. As the balls drive past the sprocket, the sprocket turns and drives the seat belt retractor spool causing the slack to be removed from the front seat belts. The ball trap captures the balls as they leave the sprocket and are expelled from the housing. Removing excess slack from the front seat belts not only keeps the occupants properly positioned for an airbag deployment following a frontal impact of the vehicle, but also helps to reduce injuries that the occupant might experience in these situations as a result of harmful contact with the steering wheel, steering column, instrument panel or windshield. Also, the seat belt tensioner torsion bar that the retractor spool rides upon is designed to deform in order to control the loading being applied to the occupants by the seat belts during a frontal impact, further reducing the potential for occupant injuries. The ORC monitors the condition of the seat belt tensioners through circuit resistance, and will illuminate the airbag indicator in the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and store a Diagnostic Trouble Code (DTC) for any fault that is detected. Proper diagnosis of the seat belt tensioner gas generator and the seat belt tensioner squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Driver Seat Track Position Sensor Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Driver Seat Track Position Sensor > Page 6178 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Driver Seat Track Position Sensor (Driver Seat) 2 Way Seat Sensor/Switch: Diagrams Driver Seat Track Position Sensor (Driver Seat) 2 Way Connector - (DRIVER SEAT) 2 WAY SENSOR-SEAT TRACK POSITION-DRIVER - (DRIVER SEAT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Driver Seat Track Position Sensor (Driver Seat) 2 Way > Page 6181 Seat Sensor/Switch: Diagrams Passenger Seat Track Position Sensor (Passenger Seat) 2 Way Connector - (PASSENGER SEAT) 2 WAY SENSOR-SEAT TRACK POSITION-PASSENGER - (PASSENGER SEAT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6187 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6188 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6189 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6190 Impact Sensor: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6191 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6192 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6193 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6194 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 6195 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way Impact Sensor: Diagrams Left Front Impact Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-FRONT IMPACT-LEFT - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 6198 Impact Sensor: Diagrams Left Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 1 - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 6199 Impact Sensor: Diagrams Right Front Impact Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-FRONT IMPACT-RIGHT - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 6200 Impact Sensor: Diagrams Right Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-RIGHT 1 - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 6201 Impact Sensor: Diagrams Left Front Impact Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-FRONT IMPACT-LEFT - (ENGINE COMPARTMENT) 2 WAY Left Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 1 - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 6202 Right Front Impact Sensor (Engine Compartment) 2 Way Connector - (ENGINE COMPARTMENT) 2 WAY SENSOR-FRONT IMPACT-RIGHT - (ENGINE COMPARTMENT) 2 WAY Right Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-RIGHT 1 - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 6203 Left Side Impact Sensor 2 (Body) 2 Way Connector - (BODY) 2 WAY SENSOR-SIDE IMPACT-LEFT 2 - (BODY) 2 WAY Right Side Impact Sensor 2 (Body) 2 Way Connector - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Front Impact Sensor (Engine Compartment) 2 Way > Page 6204 SENSOR-SIDE IMPACT-RIGHT 2 - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description Impact Sensor: Description and Operation Impact Sensor - Description Front FRONT Two front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front sensor is secured with a screw to the backs of the right and left vertical members of the radiator support within the engine compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side SIDE Four side impact sensors (1) are used on this vehicle when it is equipped with the optional side curtain airbags, two each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a screw to the inner right or left B-pillar ahead of the front seat belt retractor, and the inner quarter panel near the C-pillar beneath the trim within the passenger compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 6207 The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 6208 Impact Sensor: Description and Operation Impact Sensor - Operation Front FRONT The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the Supplemental Restraint System (SRS) electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the front impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side SIDE The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side Supplemental Restraint System (SRS) electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through the same left or right sensor plus and minus circuits in a series arrangement from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal Impact Sensor: Service and Repair Impact Sensor - Removal Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. NOTE: The front and side impact sensors are interchangeable. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the screw (4) that secures the impact sensor (3) to the of the right or left radiator support vertical member (2). 3. Disconnect the engine compartment wire harness connector (1) from the right or left front impact sensor connector receptacle. 4. Remove the right or left front impact sensor from the engine compartment. Side - B-Pillar SIDE - B-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and side impact sensors are interchangeable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 6211 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the trim from the inside of the lower right or left B-pillar (3). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. 4. Remove the screw (1) that secures the side impact sensor (2) to the lower B-pillar. 5. Disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the sensor from the B-pillar. Side - C-Pillar SIDE - C-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and side impact sensors are interchangeable. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the quarter trim panel from the inside of the lower C-pillar (1). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Remove the screw (4) that secures the side impact sensor (3) to the C-pillar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 6212 4. Disconnect the body wire harness connector (2) from the sensor (3) connector receptacle. 5. Remove the sensor from the C-pillar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 6213 Impact Sensor: Service and Repair Impact Sensor - Installation Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. NOTE: The front and side impact sensors are interchangeable. 1. Position the right or left front impact sensor (3) into the engine compartment. 2. Reconnect the engine compartment wire harness connector (1) to the sensor connector receptacle. 3. Carefully position the sensor onto the back of the right or left radiator support vertical member (2). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the radiator support. 4. Install and tighten the screw (4) that secures the sensor to the back of the support vertical member. Tighten the screw to 8 Nm (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Side - B-Pillar SIDE - B-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 6214 NOTE: The front and side impact sensors are interchangeable. 1. Reconnect the body wire harness connector (4) to the side impact sensor (2) connector receptacle. 2. Position the sensor onto the inner B-pillar (3). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the B-pillar. 3. Install and tighten the screw (1) that secures the sensor to the inner B-pillar. Tighten the screw to 8 Nm (70 in. lbs.). 4. Reinstall the lower trim onto the inside of the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation. 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Side - C-Pillar SIDE - C-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. NOTE: The front and side impact sensors are interchangeable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 6215 1. Reconnect the body wire harness connector (2) to the side impact sensor (3) connector receptacle. 2. Position the sensor onto the lower inner C-pillar (1). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the C-pillar. 3. Install and tighten the screw (4) that secures the sensor to the inner C-pillar. Tighten the screw to 8 Nm (70 in. lbs.). 4. Reinstall the quarter trim panel onto the inner lower C-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 5. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6219 Seat Belt Buckle Switch: Diagrams Connector - (BODY) 2 WAY SWITCH-SEAT BELT-DRIVER - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Seat Belt Switch - Description Seat Belt Buckle Switch: Description and Operation Seat Belt Switch - Description DESCRIPTION The seat belt switch (4) is a small, normally open, single pole, single throw, plunger (3) actuated, momentary switch. One seat belt switch is installed on the driver side front seat belt retractor frame (2) over the retractor spool (1). The seat belt switch includes an integral connector that is connected to the vehicle electrical system through a take out and connector of the body wire harness. The seat belt switch cannot be adjusted or repaired and, if ineffective or damaged, the switch unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Seat Belt Switch - Description > Page 6222 Seat Belt Buckle Switch: Description and Operation Seat Belt Switch - Operation OPERATION The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The seat belt switch plunger is actuated by the seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half, the switch plunger is extended and closes the seat belt switch sense circuit to ground. Conversely, when the seat belt tip-half webbing is wound onto the retractor spool the switch plunger is depressed, opening the ground path. The EMIC monitors the seat belt switch status, then controls the illumination of the seatbelt indicator and the generation of audible electronic chime tones based upon that input. The seat belt switch receives ground through its connection to the body wire harness from another take out of the body wire harness. An eyelet terminal connector on that ground take out is secured under a ground screw. The seat belt switch is connected in series between ground and the seat belt switch sense input of the EMIC. The seat belt switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Service and Repair > Seat Belt Switch - Removal Seat Belt Buckle Switch: Service and Repair Seat Belt Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt switch unit. The front retractor also includes a seat belt tensioner. If the front seat belt switch is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. See: Service and Repair . 1. Adjust the front seat to its most forward position for easiest access to the front seat belt lower anchor cover (1) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the driver side seat belt retractor from the lower B-pillar. See: Seat Belt Systems/Seat Belt Retractor/Service and Repair/Seat Belt Retractor - Removal. 4. Extract the seat belt webbing (1) from the retractor far enough to eliminate any contact between the seat belt switch plunger (5) and the webbing on the retractor spool. 5. Lift the latch tab (2) integral to the seat belt switch (4) far enough to allow the switch to be pushed off of the retractor frame tie bar (3). 6. Remove the seat belt switch from the retractor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Service and Repair > Seat Belt Switch - Removal > Page 6225 Seat Belt Buckle Switch: Service and Repair Seat Belt Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar(R) Parts Catalog. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt switch unit. The front retractor also includes a seat belt tensioner. If the front seat belt switch is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. See: Service and Repair . 1. Extract the seat belt webbing (1) from the retractor far enough to allow clearance between the seat belt switch plunger (5) and the webbing on the retractor spool during switch installation. 2. Position the seat belt switch (4) to the lower edge of the retractor frame tie bar (3) with the plunger oriented toward the retractor spool. 3. Push the switch onto the tie bar until the integral latch feature (2) is fully engaged over the tie bar. 4. Reinstall the driver side seat belt retractor onto the lower B-pillar. See: Seat Belt Systems/Seat Belt Retractor/Service and Repair/Seat Belt Retractor - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description Seat Position Sensor: Description and Operation Seat Track Position Sensor - Description DESCRIPTION The seat track position sensor (2) is a Hall Effect-type sensor used on some vehicles. This sensor consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the molded plastic sensor housing. The sensor housing has a mounting slot containing an integral latch feature (1) and slides and latches onto a stamped metal blade-type bracket located on the inboard side of the upper outboard seat adjuster track near the rear of both the passenger and driver front seats. A molded connector receptacle (3) integral to the sensor housing is connected to the vehicle electrical system through a connector and take out of the seat wire harness beneath the front seat cushion frame. The seat track position sensor cannot be adjusted or repaired and, if ineffective or damaged, the entire sensor must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description > Page 6230 Seat Position Sensor: Description and Operation Seat Track Position Sensor - Operation OPERATION The seat track position sensor is designed to provide a seat position data input to the Occupant Restraint Controller (ORC) indicating whether the driver or passenger front seat is in a full forward or a not full forward position. The ORC uses this data as an additional logic input for use in determining the appropriate deployment force to be used when deploying the multistage driver side front airbag. The seat track position sensor receives a nominal five volt supply from the ORC. The sensor communicates the seat position by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic Trouble Code (DTC) for any fault that is detected. The ORC then sends messages over the CAN data bus to control the illumination of the airbag indicator in the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The hard wired circuits between the seat track position sensor and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the seat track position sensor or the electronic controls and communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the seat track position sensor or the electronic controls and communication related to seat track position sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal Seat Position Sensor: Service and Repair Seat Track Position Sensor - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Reach under the front seat cushion to access the seat track position sensor (2) on a bracket located on the outboard side near the rear of the upper outboard seat track (3). 3. Using a small screwdriver, hold the latch feature (4) depressed while sliding the connector end of the sensor off of the bracket. 4. Disconnect the seat wire harness connector (1) from the sensor connector receptacle. 5. Remove the sensor from under the front seat. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal > Page 6233 Seat Position Sensor: Service and Repair Seat Track Position Sensor - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Reach under the front seat cushion to reconnect the seat wire harness connector (1) to the seat track position sensor (2) connector receptacle. Be certain that the latch on the connector is fully engaged. 2. Align the open end of the sensor to the slide tab of the sensor bracket located on the outboard side near the rear of the upper outboard seat track (3). 3. Push the sensor firmly onto the bracket until the latch feature (4) snaps into place with an audible click. 4. Do not reconnect the battery negative cable at this time. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Driver Seat Track Position Sensor Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Driver Seat Track Position Sensor > Page 6238 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Driver Seat Track Position Sensor (Driver Seat) 2 Way Seat Sensor/Switch: Diagrams Driver Seat Track Position Sensor (Driver Seat) 2 Way Connector - (DRIVER SEAT) 2 WAY SENSOR-SEAT TRACK POSITION-DRIVER - (DRIVER SEAT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Driver Seat Track Position Sensor (Driver Seat) 2 Way > Page 6241 Seat Sensor/Switch: Diagrams Passenger Seat Track Position Sensor (Passenger Seat) 2 Way Connector - (PASSENGER SEAT) 2 WAY SENSOR-SEAT TRACK POSITION-PASSENGER - (PASSENGER SEAT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair > Navigation Antenna Mast - Removal Antenna, Navigation: Service and Repair Navigation Antenna Mast - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel top cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Removal. 3. Remove the radio (4) See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Removal. 4. Remove the antenna (1) mounting fasteners 5. Remove antenna cable (3) from wire harness. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair > Navigation Antenna Mast - Removal > Page 6248 Antenna, Navigation: Service and Repair Navigation Antenna Mast - Installation INSTALLATION 1. Position antenna cable (3) to wire harness. Secure into place. 2. Install antenna (1) mounting fasteners. 3. Install radio (4) See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Installation. 4. Install instrument panel top cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Installation. 5. Connect battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Locations > Radio Antenna Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Locations > Radio Antenna > Page 6253 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Locations > Page 6254 Antenna, Radio: Diagrams Connector - (SDARS JUMPER) 2 WAY ANTENNA-SATELLITE - (SDARS JUMPER) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Description and Operation > Satellite Radio Antenna - Description Antenna, Radio: Description and Operation Satellite Radio Antenna - Description DESCRIPTION The satellite radio antenna cable connects the roof mounted antenna to the satellite receiver module. It has two connectors at each end and is routed above the headliner, then behind the left quarter panel trim. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Description and Operation > Satellite Radio Antenna - Description > Page 6257 Antenna, Radio: Description and Operation Satellite Antenna - Description DESCRIPTION The satellite radio antenna is secured by adhesive foam and retainers which protrude through a hole in the roof panel. Two wires from the antenna are connected to the body harness above the headliner. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Description and Operation > Satellite Radio Antenna - Description > Page 6258 Antenna, Radio: Description and Operation Satellite Antenna - Operation OPERATION The satellite radio antenna receives signals from orbiting satellites and sends these signals to the satellite receiver module. The satellite radio antenna must have open space in which to operate. Items carried on the roof, parking inside etc. can have an effect on the antenna's ability to receive signals. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Description and Operation > Satellite Radio Antenna - Description > Page 6259 Antenna, Radio: Description and Operation Antenna - Description DESCRIPTION Fixed Mast Antenna The antenna body and cable are secured below the fender panel by the antenna cap nut through a mounting hole in the side of the right front fender. The primary coaxial antenna cable is then routed beneath the fender sheet metal and through an entry hole in the right cowl side panel into the interior of the vehicle. Inside the vehicle, the primary coaxial cable is connected to a secondary instrument panel antenna coaxial cable with an in-line connector that is located behind the right end of the instrument panel. The secondary coaxial cable is then routed behind the instrument panel to the back of the radio. Roof Mounted Antenna The roof mounted antenna is a combination antenna that is used for the reception of Amplitude Modulation (AM) frequencies, Frequency Modulated (FM) frequencies and Satellite signals for the Digital Satellite Radio. The primary coaxial antenna cable is then routed through an entry hole in the roof panel into the interior of the vehicle. Inside the vehicle, the primary coaxial cable is connected to a secondary instrument panel antenna coaxial cable with an in-line connector that is located behind the right end of the instrument panel. The secondary coaxial cable is then routed behind the instrument panel to the back of the radio. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Description and Operation > Satellite Radio Antenna - Description > Page 6260 Antenna, Radio: Description and Operation Antenna - Operation OPERATION The antenna body and cable connects the antenna mast to the radio. The radio antenna is an electromagnetic circuit component used to capture radio frequency signals that are broadcast by local commercial radio stations in both the Amplitude Modulating (AM) and Frequency Modulating (FM) frequency ranges. These electromagnetic radio frequency signals induce small electrical modulations into the antenna as they move past the mast. The antenna body transfers the weak electromagnetic radio waves induced into the rigid antenna mast into the center conductor of the flexible primary antenna coaxial cable. The braided outer shield of the antenna coaxial cable is grounded through both the antenna body and the radio chassis, effectively shielding the radio waves as they are conducted to the radio. The radio then tunes and amplifies the weak radio signals into stronger electrical signals in order to operate the audio system speakers. For more information on the satellite radio operation of the roof mounted antenna, See: Satellite Antenna Operation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Description and Operation > Page 6261 Antenna, Radio: Testing and Inspection ANTENNA BODY AND CABLE The following four tests are used to diagnose the antenna with an ohmmeter: TEST 1 - Mast to ground test - TEST 2 - Tip-of-mast to tip-of-conductor test - TEST 3 - Body ground to battery ground test - TEST 4 - Body ground to antenna coaxial cable shield test. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. The ohmmeter test lead connections for each test are shown in the illustration. NOTE: This model has a two-piece antenna coaxial cable. Tests 2 and 4 must be conducted in two steps to isolate an antenna cable problem. First, test the primary antenna cable (integral to the antenna body and cable) from the coaxial cable connector under the right end of the instrument panel near the right cowl side inner panel to the antenna body. Then, test the secondary antenna cable (instrument panel antenna cable) from the coaxial cable connector under the right end of the instrument panel near the right cowl side inner panel to the coaxial cable connector at the radio. TEST 1 Test 1 determines if the antenna mast is insulated from ground. Proceed as follows: 1. Disconnect and isolate the antenna coaxial cable connector under the right end of the instrument panel near the right cowl side inner panel. 2. Touch one ohmmeter test lead to the tip of the antenna mast (below tip if ball tip is plastic). Touch the other test lead to the antenna cap nut. Check the ohmmeter reading for continuity. 3. There should be no continuity. If OK, go to Test 2. If not OK, replace the faulty antenna body and cable. TEST 2 Test 2 checks the antenna conductor components for an open circuit. This test should be performed first on the entire antenna circuit, from the antenna mast to the center conductor of the coaxial cable connector at the radio. If an open circuit is detected, each of the three antenna conductor components (antenna mast, antenna body and primary cable unit, instrument panel antenna secondary cable) should be isolated and tested individually to locate the exact component that is the source of the open circuit. To begin this test, proceed as follows: 1. Disconnect the instrument panel (secondary) antenna cable coaxial connector from the back of the radio. 2. Touch one ohmmeter test lead to the tip of the antenna mast. Touch the other test lead to the center conductor pin of the instrument panel antenna cable coaxial connector for the radio. Check the ohmmeter reading for continuity. 3. There should be continuity. The ohmmeter should register only a fraction of an ohm resistance. High or infinite resistance indicates a damaged or open antenna conductor. If OK, go to Test 3. If not OK, isolate and test each of the individual antenna conductor components. Replace only the Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Description and Operation > Page 6262 faulty antenna conductor component. TEST 3 Test 3 checks the condition of the vehicle body ground connection. To begin this test, proceed as follows: 1. This test must be performed with the battery positive cable disconnected from the battery. Disconnect and isolate both battery cables, negative cable first. 2. Reconnect the battery negative cable. 3. Touch one ohmmeter test lead to a good clean ground point on the vehicle fender. Touch the other test lead to the battery negative terminal post. Check the ohmmeter reading for continuity. 4. There should be continuity. The ohmmeter should register less than one ohm resistance. High or infinite resistance indicates a loose, corroded, or damaged connection between the battery negative terminal and the vehicle body. If OK, go to Test 4. If not OK, check the battery negative cable connection to the vehicle body and the radio noise suppression ground strap connections to the engine and the vehicle body for being loose or corroded. Clean or tighten these connections as required. TEST 4 Test 4 checks the condition of the connection between the antenna coaxial cable shield and the vehicle body ground as follows: 1. Disconnect and isolate the antenna coaxial cable connector under the right end of the instrument panel near the right cowl side inner panel. 2. Touch one ohmmeter test lead to a good clean ground point on the vehicle fender. Touch the other test lead to the outer crimp on the antenna coaxial cable connector under the right end of the instrument panel near the right cowl side inner panel. Check the ohmmeter reading for continuity. 3. There should be continuity. The ohmmeter should register less than one ohm resistance. High or infinite resistance indicates a loose, corroded, or damaged connection between the antenna body and the vehicle body or between the antenna body and the antenna coaxial cable shield. If not OK, clean the antenna body to fender mating surfaces and tighten the antenna cap nut to specifications. 4. Check the resistance again with an ohmmeter. If the resistance is still more then one ohm, replace the faulty antenna body and cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Service and Repair > Satellite Radio Antenna - Removal Antenna, Radio: Service and Repair Satellite Radio Antenna - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear quarter trim panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Lower the rear portion of the headliner as necessary to access the underside of the satellite antenna See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Removal. 4. Detach the antenna cable (1) from the body harness. Disconnect wire harness connectors at each end of the cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Service and Repair > Satellite Radio Antenna - Removal > Page 6265 Antenna, Radio: Service and Repair Satellite Radio Antenna - Installation INSTALLATION 1. Secure the antenna cable (1) to the body harness. Connect the wire harness connectors at each end of the antenna. 2. Install the headliner See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation. 3. Install the rear quarter trim panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Service and Repair > Satellite Radio Antenna - Removal > Page 6266 Antenna, Radio: Service and Repair Satellite Antenna - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Lower the rear portion of the headliner as necessary to access underside of antenna (1)See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Removal. 3. An adhesive removal tool can be created by using an 18 to 24 inch piece of nylon cord (2) wrapped around two handles (3). Using the removal tool, guide the nylon cord under the dust seal on the forward side of the antenna. Grab the handles and work the cord through the adhesive. Continue this for 360° around the antenna. 4. Disconnect the wire harness connectors from the antenna. 5. From inside the vehicle, and using a flat bladed tool, depress one of the retaining tabs on the antenna. Push up the one side of the antenna connector through the roof panel. Depress the other side of the connector and remove the antenna. 6. Remove any remaining adhesive from roof panel with isopropyl alcohol and a lint free cloth. If original antenna is being reinstalled, remove adhesive from antenna mounting surface. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Service and Repair > Satellite Radio Antenna - Removal > Page 6267 Antenna, Radio: Service and Repair Satellite Antenna - Installation INSTALLATION 1. If original antenna is being reinstalled, remove backing from patch adhesive (2) and apply to antenna base (1). 2. Remove backing from the adhesive on the antenna. 3. Insert wire harness through hole in roof panel. Press antenna into position until both retainers snap into place. 4. Connect wire harness connectors to antenna. 5. Install headliner See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation. 6. Connect battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Service and Repair > Satellite Radio Antenna - Removal > Page 6268 Antenna, Radio: Service and Repair Satellite Radio Antenna - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear quarter trim panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Lower the rear portion of the headliner as necessary to access the underside of the satellite antenna See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Removal. 4. Detach the antenna cable (1) from the body harness. Disconnect wire harness connectors at each end of the cable. Satellite Radio Antenna - Installation INSTALLATION 1. Secure the antenna cable (1) to the body harness. Connect the wire harness connectors at each end of the antenna. 2. Install the headliner See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation. 3. Install the rear quarter trim panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 4. Connect the battery negative cable. Satellite Antenna - Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Service and Repair > Satellite Radio Antenna - Removal > Page 6269 1. Disconnect and isolate the battery negative cable. 2. Lower the rear portion of the headliner as necessary to access underside of antenna (1)See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Removal. 3. An adhesive removal tool can be created by using an 18 to 24 inch piece of nylon cord (2) wrapped around two handles (3). Using the removal tool, guide the nylon cord under the dust seal on the forward side of the antenna. Grab the handles and work the cord through the adhesive. Continue this for 360° around the antenna. 4. Disconnect the wire harness connectors from the antenna. 5. From inside the vehicle, and using a flat bladed tool, depress one of the retaining tabs on the antenna. Push up the one side of the antenna connector through the roof panel. Depress the other side of the connector and remove the antenna. 6. Remove any remaining adhesive from roof panel with isopropyl alcohol and a lint free cloth. If original antenna is being reinstalled, remove adhesive from antenna mounting surface. Satellite Antenna - Installation INSTALLATION 1. If original antenna is being reinstalled, remove backing from patch adhesive (2) and apply to antenna base (1). 2. Remove backing from the adhesive on the antenna. 3. Insert wire harness through hole in roof panel. Press antenna into position until both retainers snap into place. 4. Connect wire harness connectors to antenna. 5. Install headliner See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation. 6. Connect battery negative cable. Antenna - Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Service and Repair > Satellite Radio Antenna - Removal > Page 6270 1. Disconnect and isolate the battery negative cable. 2. Remove antenna mast by unscrewing mast from antenna body. On vehicles equipped with manual retractable antenna, lower antenna fully. 3. Remove shroud (1), if equipped. 4. Remove antenna nut (2) and adapter (3) 5. Disconnect antenna body cable from instrument panel antenna cable. 6. Remove inner fender shield as necessary to gain access to mounting fasteners. 7. Remove antenna body and cable (2) assembly from fender (1) Antenna - Installation INSTALLATION 1. Position antenna body and cable assembly (2) into fender (1). 2. Insert antenna cable through the opening in fender. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Component Information > Service and Repair > Satellite Radio Antenna - Removal > Page 6271 3. Seat the grommet in the side panel and connect the cable to the instrument panel harness connector. 4. Install antenna nut (2) and adapter (3). 5. Install shroud (1), if equipped. 6. Install the inner fender shield. 7. Install antenna mast. Tighten to 5 Nm (46 in. lbs.). Ensure that the antenna mast is fully seated on antenna base and that there is no gap between the mast and base. 8. Connect the antenna cable to the instrument panel antenna cable. 9. Install the right side cowl trim panel. 10. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Horn > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Sentry Key Immobilizer Module (SKREEM) - Description Alarm Module: Description and Operation Sentry Key Immobilizer Module (SKREEM) - Description DESCRIPTION When a PCM and the SKREEM are replaced at the same time, perform the following steps in order: 1. Program the new PCM. 2. Program the new SKREEM. 3. Replace all ignition keys and program them to the new SKREEM.See: Keyless Entry/Keyless Entry Module/Testing and Inspection/Programming and Relearning The Sentry Key REmote Entry Module (SKREEM) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM/WCM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system and the Tire Pressure Monitor (TPM) system. The SKREEM/WCM is located on the steering column, around the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM/WCM has an integral molded plastic halo-like antenna ring (3) that extends from one side. When the SKREEM/WCM is properly installed, the antenna ring is oriented around the ignition lock cylinder housing. A single connector (4) is located next to the antenna ring on the SKREEM/WCM housing (3). A molded plastic mounting tab (2) on the SKREEM/WCM housing secures the unit to the steering column. The SKREEM/WCM is connected to the vehicle electrical system through the instrument panel wire harness. The SKREEM/WCM cannot be adjusted or repaired. If faulty or damaged, the entire SKREEM unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Sentry Key Immobilizer Module (SKREEM) - Description > Page 6280 Alarm Module: Description and Operation Sentry Key Immobilizer Module (SKREEM) - Operation OPERATION The Sentry Key REmote Entry Module (SKREEM), sometimes referred to as the Wireless Control Module (WCM), contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM/WCM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM/WCM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM/WCM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver and, if the vehicle is so equipped, the receiver for the Tire Pressure Monitoring (TPM) system. See: Body and Frame/Locks/Power Locks/Description and Operation/Power Locks - Description or See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Description and Operation/Tire Pressure Monitoring (TPM) - Description. The SKREEM/WCM communicates over the Controller Area Network (CAN) data bus with the Electro Mechanical Instrument Cluster (EMIC) (sometimes referred to as the Cab Compartment Node (CCN), the Powertrain Control Module (PCM), and/or the diagnostic scan tool. The SKREEM/WCM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM/WCM. For added system security, each SKREEM/WCM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM/WCM. Therefore, the Secret Key code is a common element that is found in every component of the Sentry Key Immobilizer System (SKIS). Another security code, called a PIN, is used to gain access to the SKREEM/WCM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. See: Service and Repair See: Alarm System Transponder/Testing and Inspection The SKREEM/WCM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM during SKIS initialization. NOTE: After a SKREEM/WCM is replaced, the ignition/transponder keys need to be programmed to the new SKREEM/WCM. Follow the directions on the diagnostic scan tool. The transponder key for the SKREES/SKIM and the RKE will both be programmed during this operation. There is no need to program the fob of the key for RKE functionality once the transponder key is programmed to the new SKREEM/WCM. In the event that a SKREEM/WCM replacement is required, the Secret Key code can be transferred to the new SKREEM/WCM from the PCM using the diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM/WCM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM/WCM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On position, the SKREEM/WCM transmits an RF signal to the transponder in the ignition key. The SKREEM/WCM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM/WCM sends a valid key message to the PCM over the CAN data bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM/WCM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKREEM/WCM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKREEM/WCM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM/WCM also sends security indicator status messages to the EMIC/CCN over the CAN data bus to tell the EMIC/CCN how to operate the security indicator. The security indicator status message from the SKREEM/WCM tells the EMIC/CCN to turn the indicator on for about three seconds each time the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKREEM/WCM sends security indicator status messages to the EMIC/CCN to turn the indicator off, turn the indicator on, or to flash the indicator on and off. If the security indicator flashes or stays on solid after the bulb test, it signifies a SKIS fault. If the SKREEM/WCM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKREEM/WCM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM/WCM will also send messages to the EMIC/CCN to flash the security indicator whenever the Customer Learn programming mode is being utilized . See: Alarm System Transponder/Testing and Inspection The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM/WCM memory if a system malfunction is detected. The SKREEM/WCM can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal Alarm Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Removal REMOVAL NOTE: The steering wheel does not have to be removed to service the SKREEM/WCM. NOTE: The Steering Column Control Module (SCCM) assembly, which consists of the left/right multi-function switches and the clockspring, does not have to be removed to service the SKREEM/WCM. There is an access hole in the top of the right multi-function switch to access the mounting screw (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the upper and lower steering column shrouds See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the SKREEM/WCM mounting screw (2) on the ignition lock assembly and separate the SKREEM/WCM (3) from the ignition lock assembly. 4. Disconnect the SKREEM/WCM electrical connector (4). 5. Remove SKREEM/WCM (1 and 3) from column (2). When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Keyless Entry/Keyless Entry Module/Testing and Inspection/Programming and Relearning. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 6283 - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 6284 Alarm Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Installation INSTALLATION When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Keyless Entry/Keyless Entry Module/Testing and Inspection/Programming and Relearning. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. 1. Position the SKREEM/WCM (3) on the ignition lock housing and install the retaining screw (2). 2. Connect the SKREEM/WCM electrical connector (4). NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated . See: Alarm System Transponder/Testing and Inspection 3. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Transponder Key - Description Alarm System Transponder: Description and Operation Transponder Key - Description DESCRIPTION Each ignition key (2) used in the Sentry Key REmote Entry System (SKREES) has a transponder chip included on the circuit board (4) beneath the cover (1) of the integral Remote Keyless Entry (RKE) transmitter (3). In addition to having to be cut to match the mechanical coding of the ignition lock cylinder and programmed for operation of the RKE system, each new Sentry Key has a unique transponder identification code that is permanently programmed into it by the manufacturer, and which must be programmed into the Sentry Key REmote Entry Module (SKREEM), sometimes referred to as the Wireless Control Module (WCM), to be recognized by the SKREES as a valid key. The Sentry Key transponder cannot be adjusted or repaired. If faulty or damaged, the entire key and RKE transmitter unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Transponder Key - Description > Page 6289 Alarm System Transponder: Description and Operation Transponder Key - Operation OPERATION When the ignition switch is turned to the On position, the Sentry Key REmote Entry Module (SKREEM), sometimes referred to as the Wireless Control Module (WCM), communicates through its antenna with the Sentry Key transponder using a Radio Frequency (RF) signal. The SKREEM/WCM then listens for a RF response from the transponder through the same antenna. The Sentry Key transponder chip is within the range of the SKREEM/WCM transceiver antenna ring when it is inserted into the ignition lock cylinder. The SKREEM/WCM determines whether a valid key is present in the ignition lock cylinder based upon the response from the transponder. If a valid key is detected, that fact is communicated by the SKREEM/WCM to the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus, and the PCM allows the engine to continue running. If the PCM receives an invalid key message, or receives no message from the SKREEM/WCM over the CAN data bus, the engine will be disabled after about two seconds of operation. The Electro Mechanical Instrument Cluster (EMIC), sometimes referred to as the Cab Compartment Node (CCN), will also respond to the invalid key message on the CAN data bus by flashing the security indicator on and off. Each Sentry Key has a unique transponder identification code permanently programmed into it by the manufacturer. Likewise, the SKREEM/WCM has a unique Secret Key code programmed into it by the manufacturer. When a Sentry Key is programmed into the memory of the SKREEM/WCM, the SKREEM/WCM stores the transponder identification code from the Sentry Key, and the Sentry Key learns the Secret Key code from the SKREEM/WCM. Once the Sentry Key learns the Secret Key code of the SKREEM/WCM, it is permanently stored in the memory of the transponder. Therefore, once a Sentry Key has been programmed to a particular vehicle, it cannot be used on any other vehicle See: Testing and Inspection The Sentry Key REmote Entry System (SKREES) performs a self-test each time the ignition switch is turned to the On position, and will store key-related fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM/WCM memory if a Sentry Key transponder problem is detected. The Sentry Key transponder chip can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Refer to the appropriate diagnostic information. Common communication problems: - Two transponder keys too close together. - Speed Pass too close to transponder key. - Loss of PCM communication. - Failed antenna circuit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Page 6290 Alarm System Transponder: Testing and Inspection TRANSPONDER PROGRAMMING All Sentry Keys included with the vehicle are pre-programmed to work with the Sentry Key Remote Entry System (SKREES) when it is shipped from the factory. The Sentry Key REmote Entry Module (SKREEM) can be programmed to recognize up to a total of eight Sentry Keys. When programming a blank Sentry Key transponder, the key must first be cut to match the ignition switch lock cylinder in the vehicle for which it will be used. Once the additional or new key has been cut, the SKREEM must be programmed to recognize it as a valid key. There are two possible methods to program the SKREEM to recognize a new or additional valid key, the Secured Access Method and the Customer Learn Method. Following are the details of these two programming methods. SECURED ACCESS METHOD The Secured Access method applies to all vehicles. This method requires the use of a diagnostic scan tool. This method will also require that you have access to the unique four-digit PIN code that was assigned to the original SKREEM. The PIN code must be used to enter the Secured Access Mode in the SKREEM. This PIN number may be obtained from the vehicle owner, from the original vehicle invoice, or from the Chrysler Customer Center. Refer to the appropriate diagnostic information for the proper Secured Access method programming procedures. NOTE: The Remote Keyless Entry (RKE) Transmitter will also be programmed during this procedure. CUSTOMER LEARN METHOD The Customer Learn feature is only available on domestic vehicles, or those vehicles which have a U.S. country code designator. This programming method also requires access to at least two valid Sentry Keys. If two valid Sentry Keys are not available, or if the vehicle does not have a U.S. country code designator, the Secured Access Method must be used to program new or additional valid keys to the SKREEM. The Customer Learn programming method procedures are as follows: 1. Obtain the blank Sentry Key(s) that are to be programmed as valid keys for the vehicle. Cut the blank key(s) to match the ignition switch lock cylinder mechanical key codes. 2. Insert one of the two valid Sentry Keys into the ignition switch and turn the ignition switch to the On position. 3. After the ignition switch has been in the On position for longer than 3 seconds, but no more than 15 seconds, cycle the ignition switch back to the Off position. Replace the first valid Sentry Key in the ignition switch lock cylinder with the second valid Sentry Key and turn the ignition switch back to the On position. The second valid Sentry Key must be inserted in the lock cylinder within 15 seconds of removing the first valid key. 4. About 10 seconds after the completion of 3 , the security indicator in the instrument cluster will start to flash to indicate that the system has entered the Customer Learn programming mode. 5. Within 60 seconds of entering the Customer Learn programming mode, turn the ignition switch to the Off position, replace the valid Sentry Key with a blank Sentry Key transponder, and turn the ignition switch back to the On position. 6. About 10 seconds after the completion of 5 , the security indicator will stop flashing, stay on solid for 3 seconds, then turn off to indicate that the blank Sentry Key has been successfully programmed. The SKREES will immediately exit the Customer Learn programming mode. After the ignition is cycled the vehicle may be started using the newly programmed valid Sentry Key. NOTE: The Remote Keyless Entry (RKE) Transmitter will also be programmed during this procedure. Each of these steps must be repeated and completed in their entirety for each additional Sentry Key that is to be programmed. If the above steps are not completed in the given sequence, or within the allotted time, the SKREEM will exit the Customer Learn programming mode and the programming will be unsuccessful. The SKREEM will also automatically exit the Customer Learn programming mode if it sees a non-blank Sentry Key transponder when it should see a blank, if it has already programmed eight (8) valid Sentry Keys, or if the ignition switch is turned to the Off position for more than about 50 seconds. NOTE: If an attempt is made to start the vehicle while in the Customer Learn mode (security indicator flashing), the SKIS will respond as though the vehicle were being started with an invalid key. In other words, the engine will stall after about two seconds of operation. No faults will be set. NOTE: Once a Sentry Key has been programmed as a valid key to a vehicle, it cannot be programmed as a valid key for use on any other vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6298 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY MODULE-SENTRY KEY REMOTE ENTRY/WCM - (INSTRUMENT PANEL) 8 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Keyless Entry Module: Initial Inspection and Diagnostic Overview REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic information. Refer to the appropriate wiring information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6301 Keyless Entry Module: Programming and Relearning SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6302 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) Removal Keyless Entry Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Removal REMOVAL NOTE: The steering wheel does not have to be removed to service the SKREEM/WCM. NOTE: The Steering Column Control Module (SCCM) assembly, which consists of the left/right multi-function switches and the clockspring, does not have to be removed to service the SKREEM/WCM. There is an access hole in the top of the right multi-function switch to access the mounting screw (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the upper and lower steering column shrouds See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the SKREEM/WCM mounting screw (2) on the ignition lock assembly and separate the SKREEM/WCM (3) from the ignition lock assembly. 4. Disconnect the SKREEM/WCM electrical connector (4). 5. Remove SKREEM/WCM (1 and 3) from column (2). When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Testing and Inspection/Programming and Relearning. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) Removal > Page 6305 - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) Removal > Page 6306 Keyless Entry Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Installation INSTALLATION When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Testing and Inspection/Programming and Relearning. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. 1. Position the SKREEM/WCM (3) on the ignition lock housing and install the retaining screw (2). 2. Connect the SKREEM/WCM electrical connector (4). NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated . See: Alarm System Transponder/Testing and Inspection 3. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair RKE TRANSMITTER BATTERIES The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves near the key ring until the two halves unsnap. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the two batteries with new Panasonic 2016, or equivalent. Be certain that the batteries are installed with their polarity correctly oriented. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together until they snap back into place. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Navigation/Telecommunication - Description Cellular Phone: Description and Operation Navigation/Telecommunication - Description DESCRIPTION TELECOMMUNICATION The hands-free cellular system on this vehicle uses Bluetooth(TM) technology to provide wireless communication between the operator's compatible cellular telephone and the vehicle's on-board receiver. The system uses voice recognition technology to control operation. The incoming voice is broadcast through the vehicle's radio speakers, automatically overriding any other audio signals on the front speakers when the hands-free system is in use. A microphone in the rearview mirror picks up vehicle occupant's voices. The system will communicate with a telephone that is anywhere within the vehicle. However, covering the hand held phone or the hands-free phone module with a metal object may block the signal. The system will recognize up to seven Bluetooth(TM) cellular phones, each of which is given a spoken identification by the user during the setup process. The system includes Spanish voice recognition in addition to English. Two buttons on the rearview mirror, identified with ISO icons, control the system: A "phone" button turns the system on and off; a "voice recognition" (or voice command) button prompts the hands-free system to listen for a voice command. NAVIGATION The navigation system offers several new customer features for expanded usability and convenience with hands-free voice-activated operation in addition to the touch screen buttons. The navigation system uses the Bluetooth microphone in the rear view mirror. Navigation routes can be based on a variety of formats including some of the following: - Destination entry by street intersection, city, zip code, street name, street address and number, state/province/country and phone number - Stop/change route - Save current position - Personal menu, including Guide Me Home (Go Home), Trip Itinerary, List of Saved Locations, Favorite Points of Interest (from a data base), Manage Personal User and Choose User - Personal Interests including recent routes, address book, Where Am I Now, Emergency (police stations, Dodge dealerships, fire stations, hospitals and emergency care centers), Trail and geocoordinates - Route options include shortest, quickest, maximize freeways, minimize freeways, avoid toll roads and avoid ferries - Navigation can be put into DEMO mode to enhance trip planning This navigation system will support Traffic Messaging. Traffic Messaging displays voice and pop up warning messages for medium and high priority situations on the route such as road closures due to accidents/hazardous situations and it can even generate a traffic detour for a traffic event located on the route. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Navigation/Telecommunication - Description > Page 6315 Cellular Phone: Description and Operation Navigation/Telecommunication - Operation OPERATION TELECOMMUNICATION Two buttons on the rearview mirror, identified with ISO icons, control the system: A "phone" button turns the system on and off; a "voice recognition" (or voice command) button prompts the hands-free system to listen for a voice command. The system includes the following features: - Phone book - Stores telephone numbers for later recall by name or other verbal identification, called a voice tag, and memory location. - Four memory locations - Home, Work, Cellular and Pager. A maximum of 32 unique names or voice tags may be stored at the same time, with a different number in each of the four memory locations. - Voice tag dialing - Dials the number associated with a voice tag and memory location. - Digit dialing - Dials the telephone number by recognizing the names of the digits as they are spoken. - Receiving calls - A voice prompt notifies the user of an incoming call. A voice response accepts or rejects the call without manual intervention. - Privacy Mode - Switches the call to the handheld telephone and the hands-free system and back again using the "voice recognition" (or "voice command") button and a voice command, if desired. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Page 6316 Cellular Phone: Testing and Inspection TELECOMMUNICATIONS Any diagnosis of the Telecommunication system should begin with the use of scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Service information. For complete circuit diagrams, refer to the appropriate wiring information. WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. TELECOMMUNICATION SYSTEM DIAGNOSIS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Page 6317 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Page 6318 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Hands Free Module (HFM) - Removal Cellular Phone: Service and Repair Hands Free Module (HFM) - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel end cap. 3. Remove the instrument panel steering column cover. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 4. Remove the module mounting fasteners. 5. Disconnect the electrical harness connector and remove module. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Hands Free Module (HFM) - Removal > Page 6321 Cellular Phone: Service and Repair Hands Free Module (HFM) - Installation INSTALLATION 1. Connect electrical harness connector and position module. 2. Install module mounting fasteners. 3. Install the instrument panel steering column cover. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 4. Install the instrument panel end cap. 5. Connect battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6327 It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6328 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6329 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6330 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6331 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6332 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6333 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6334 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6335 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6336 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6337 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6338 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6339 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6340 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6341 Driver/Vehicle Information Display: Connector Views Electronic Overhead Module C1 (Headliner) 3 Way Connector C1 - (HEADLINER) 3 WAY MODULE-ELECTRONIC OVERHEAD - (HEADLINER) 3 WAY Electronic Overhead Module C2 (Headliner) 4 Way Connector C2 - (HEADLINER) 4 WAY MODULE-ELECTRONIC OVERHEAD - (HEADLINER) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6342 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Electronic Vehicle Information Center - Description Driver/Vehicle Information Display: Description and Operation Electronic Vehicle Information Center - Description DESCRIPTION The base instrument cluster can be identified by the single TRIP SHAFT button (18) located to the left of the Temperature Gauge (3). The odometer display (15) doubles as the outside air temperature display when selected by toggling through the odometer menu using the TRIP SHAFT button. The Electronic Vehicle Information Center (EVIC) features a driver-interactive display (29). The display is located in the lower left part of the instrument cluster below the fuel and engine temperature gauges (1 and 3). This system conveniently allows the driver to select a variety of useful information by pressing the STEP button (28) to the right of the EVIC display. The EVIC displays information related to the following: - System Status - Vehicle information warning message displays - Personal Settings (customer programmable features) - Compass display - Outside temperature display - Trip computer functions - Connect(TM) hands-free communication system displays - If Equipped - Navigation system screens - If Equipped - Audio mode display The EVIC system is comprised of several different components. Those components are: - Instrument Cluster - EVIC STEP Button Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Electronic Vehicle Information Center - Description > Page 6345 - Ambient Temperature Sensor - Remote Compass Module (RCM) - Controller Area Network (CAN) Data Bus - Local Interface Network (LIN) Data Bus The EVIC display and STEP button are part of the Instrument Cluster assembly and cannot be serviced as separate components. If the display or button are inoperative the complete Instrument Cluster assembly must be replaced, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Electronic Vehicle Information Center - Description > Page 6346 Driver/Vehicle Information Display: Description and Operation Electronic Vehicle Information Center - Operation OPERATION The Electronic Vehicle Information Center (EVIC) uses both non-switched and ignition switched sources of battery current so that some of its features remain operational at any time, while others may only operate with the ignition switch in the On position. When the ignition switch is turned to the On position, the EVIC display (29) will return to the last function being displayed before the ignition was turned to the Off position. The EVIC system is comprised of several different components that communicate over the Controller Area Network (CAN) and Local Interface Network (LIN) Data Buses. If the system is inoperative a scan tool and the appropriate diagnostic information must be used to diagnose the system and related data buses. The instrument cluster STEP button (28) is used to operate the different functions of the EVIC system. Pressing and releasing the STEP button will scroll through the following displays: - Compass/Temperature/Audio - Average Fuel Economy - Distance to Empty - Elapsed Time - Personal Settings Once a particular system is displayed, short and long presses of the STEP button will move the EVIC through the system menu. Pressing and holding the STEP button once will clear the reset table function currently being displayed. Reset will only occur if a resettable function is currently being displayed. To reset all resettable functions, press and release the STEP button a second time within 3 seconds of resetting the currently displayed function (Reset ALL will be displayed during this 3 second window). EVIC DISPLAY MODES SYSTEM STATUS MODE System display mode displays warnings and user interaction messages on the EVIC display (29). The driver can scroll to view multiple messages by using the STEP button. When the appropriate conditions exist, the EVIC displays the following messages: - Turn Signal On (with a continuous warning chime) - Left Front Turn Signal Lamp Out (with a single chime) - Left Rear Turn Signal Lamp Out (with a single chime) - Right Front Turn Signal Lamp Out (with a single chime) - Right Rear Turn Signal Lamp Out (with a single chime) - Personal Settings Not Available - Vehicle Not in Park (automatic transmissions) or vehicle in motion (manual transmissions) - Left/Right Front Door Ajar (one or more, with a single chime if speed is above 1 mph (1.6 km/h)) - Left/Right Rear Door Ajar (one or more, with a single chime if speed is above 1 mph (1.6 km/h)) - Door(s) Ajar (with a single chime if vehicle is in motion) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Electronic Vehicle Information Center - Description > Page 6347 - Trunk Ajar (with a single chime) - Headlamps On/Lights On With Key Out Of Ignition. COMPASS/TEMPERATURE/AUDIO Compass heading and outside temperature are displayed at the top of the EVIC display screen. On the lower half of the screen the audio mode is displayed along with the odometer. One of eight compass headings to indicate the direction the vehicle is facing (N, S, E, W, NE, NW, SE, SW) and to select one of 15 compass variance settings. Outside temperature is displayed in °C (degrees Celsius) or °F (degrees Fahrenheit). Audio mode can display any one of 12 radio station preset frequencies, CD disc number, CD track number, tape, and one of 200 Satellite Radio Channels - if equipped. For additional information regarding the compass, refer to Personal Settings (Customer Programmable Features). AVERAGE FUEL ECONOMY Shows the average fuel economy since the last reset. When the fuel economy is reset, the display will read "RESET" or show dashes for two seconds. Then, the history information will be erased, and the averaging will continue from where it was before the reset. DISTANCE TO EMPTY (DTE) NOTE: Significant changes in driving style or vehicle loading will greatly affect the actual drivable distance of the vehicle, regardless of the DTE displayed value. Shows the estimated distance that can be travelled with the fuel remaining in the tank. This estimated distance is determined by a weighted average of the instantaneous and average fuel economy, according to the current fuel tank level. This is not resettable. When the DTE value is less than 30 miles (48 kilometers) estimated driving distance, the DTE display will change to a text display of "LOW FUEL". This display will continue until the vehicle runs out of fuel. Adding a significant amount of fuel to the vehicle will turn off the "LOW FUEL" text and a new DTE value will be displayed, based on the current values in the DTE calculation and the current fuel tank level. ELAPSED TIME Shows the total elapsed time of travel since the last reset when the ignition switch is in the ACC position. Elapsed time will increment when the ignition switch is in the ON or START position. HANDS FREE TELEPHONE MODE - IF EQUIPPED Provides the following information and features for the optional hands-free communications system: - Phone status: idle, voice mail, roaming, battery strength and signal strength in increments of 20 percent - Call status: Incoming call, connecting, connected, air time in minutes and seconds, call ended, busy, call failed, roaming and no phone connection - Caller ID phone number display PERSONAL SETTINGS MODE (CUSTOMER PROGRAMMABLE FEATURES) Allows the driver to set and recall features when the transmission is in Park by pressing and releasing the STEP button until Personal Settings is displayed in the EVIC. The following personal settings can be set and recalled: - Language: English, Spanish and French (domestic markets) German and Italian (export markets) - Lock doors automatically at 15 mph (24 km/h), On or Off - Unlock door automatically on exit, On or Off - Remote Keyless Entry unlock driver door on first press or unlock all doors on first press - Sound horn with Remote Keyless Entry Lock, On or Off - Turn headlamps on with Remote Keyless Entry Lock, On or Off - Delay turning headlamps off for 0, 30, 60 or 90 seconds - Key-Off Power Delay (delay power off to accessories until exit off, 45-seconds maximum, 5-minute maximum, 10-minute maximum) - Illuminated Approach - Turn headlamps on with Remote Keyless Entry Unlock, Off or 30, 60 or 90 seconds - Display units in English or Metric - Compass Variance Setting 1 through 15 - Calibrate Compass Yes/No Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 6348 Driver/Vehicle Information Display: Testing and Inspection ELECTRONIC VEHICLE INFORMATION CENTER CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDA's, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. The Electronic Vehicle Information Center (EVIC) data is obtained from several components on the Controller Area Network (CAN) and Local Interface Network (LIN) Data Bus circuits. The EVIC will not function properly if the bus messages from any of these components is not received. If no EVIC data is displayed or the display indicates dashes "- -", check the CAN Data Bus circuit communications, the Instrument Cluster functions, the Remote Compass Module (RCM) and the Totally Integrated Power Module (TIPM). The use of a scan tool and the proper diagnostic procedures information are recommended for further testing of the EVIC, the RCM, the CAN Data Bus and Local Interface Network (LIN) Data Bus circuits. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Compass Calibration Driver/Vehicle Information Display: Adjustments Compass Calibration COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDA's, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. The electronic compass unit features a continuous self-calibrating feature. This feature automatically updates the compass calibration as the vehicle is driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or the Electronic Vehicle Information Center (EVIC) displays "CAL", perform the following calibration procedure. Also, any time a new RCM is installed, it must be calibrated using this procedure. Calibrate the compass manually as follows: NOTE: Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. 1. Start the engine but leave the vehicle in "PARK". 2. Continue to depress and release the STEP button (28) until the "Personal Settings" menu is displayed. 3. Once in the "Personal Settings" menu depress and release the STEP button (28) several times until "Calibrate Compass (Yes)" is displayed. 4. A long (longer than two seconds) STEP button press will place the compass in calibration mode. The "Cal" indicator will change from flashing to on continuously in the EVIC display (29) to indicate that the compass is now in the calibration mode and that the vehicle can now be driven to calibrate. (A short STEP button press from the "Calibrate Compass (Yes)" screen will exit the EVIC Customer Programmable features, and return it to its normal operating mode). 5. To complete the compass calibration, drive the vehicle in one or more complete 360 degree circles under 5 mph (8 km/h) in an area free of large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines, until the "CAL" indicator turns off. The compass will now function normally. NOTE: If the compass display indicates an inaccurate compass heading or the display is locked up, the RCM may be inoperative or the vehicle may need to be demagnetized. Perform the Compass Demagnetizing Procedure prior to performing any system diagnosis, See: . NOTE: If the compass display indicates dashes "- -" the RCM may be inoperative or the vehicle may need to be demagnetized. Perform the Compass Demagnetizing Procedure prior to performing any system diagnosis, See: . NOTE: If the "CAL" message remains in the display or if the compass heading is inaccurate following the calibration procedure and there are no internal compass faults, either there is excessive magnetism near the compass, or the unit is inoperative. Repeat the calibration procedure at least one more time prior to performing any system diagnosis. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the calibration procedure in another location. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Compass Calibration > Page 6351 Driver/Vehicle Information Display: Adjustments Compass Variance Adjustment COMPASS VARIANCE ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give inaccurate readings. To optimize compass accuracy, the compass variance should be properly set according to the compass variance map zone for the region that the vehicle is in. To set the compass variance: 1. Using the Variance Settings map, find your geographic location and note the zone number. 2. Turn the ignition switch to the On position. 3. Continue to depress and release the STEP button (28) until the "Personal Settings" menu is displayed. 4. Once in the "Personal Settings" menu depress and release the STEP button (28) several times until "Compass Variance" is displayed. The "Compass Variance" message and the current variance zone number will be displayed. The default variance zone is 8. NOTE: During programming, the Zone value will wrap around from Zone 15 to Zone 1. 5. To change the zone, press and hold (longer than two seconds) the STEP button to increment the variance one step. Repeat as necessary, with individual long (longer than two seconds) STEP button presses for each increment, until the desired variance is achieved. 6. To exit the Variance Programming, press the STEP button with a short (less than one second) button press. 7. Confirm that the correct directions are now indicated by the compass. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures Driver/Vehicle Information Display: Procedures COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 3. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 4. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 5. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 6. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 7. Calibrate the compass, See: Adjustments and adjust the compass variance, See: Adjustments. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 6354 Driver/Vehicle Information Display: Removal and Replacement Electronic Vehicle Information Center - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: RHD model shown in illustration. LHD model similar. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel upper panel, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Pad - Removal. 3. Remove the screws (6) securing the Remote Compass Module (RCM) (5) to the instrument panel. 4. Disconnect the RCM electrical connector (1) and remove the RCM from the vehicle. Electronic Vehicle Information Center - Installation INSTALLATION NOTE: RHD model shown in illustration. LHD model similar. 1. Position the Remote Compass Module (RCM) (5) on top of the instrument panel. 2. Install the screws (6) that secure the RCM to the instrument panel. 3. Connect the RCM electrical connector (1). 4. Install the instrument panel upper panel, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Pad - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 6355 5. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 6356 Driver/Vehicle Information Display: Tools and Equipment SPECIAL TOOLS DEGAUSSING TOOL 6029 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Entertainment System - Disabling Front Seat Video Source DVD Player: Technical Service Bulletins Entertainment System - Disabling Front Seat Video Source NUMBER: 08-004-10 GROUP: Electrical DATE: March 2, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-002-2007 DATED FEBRUARY 6, 2007. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Radio Video Disable Update MODELS: 2010 (D1) Ram Truck (3500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2008 - 2009 (HB) Durango 2008-2009 (HG) Aspen 2008-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2007 - 2010 (JS) Sebring/Avenger/Sebring Convertible 2007-2010 (KA) Nitro 2008-2010 (KK) Liberty 2008 - 2010 (LC) Challenger 2008 - 2010 (LX) 300/ 300C, Charger 2009-2010 (MK) Patriot 2008-2010 (ND) Dakota 2008-2010 (PM) Caliber 2008 - 2010 (RT) Town & Country/Grand Caravan 2008 - 2010 (WK) Grand Cherokee 2008 - 2010 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a Hard Drive Radio (sales code REN, RER, REU, RBZ, RHR). NOTE: Refer to Warranty Bulletin D-07-04 for additional information and a listing of affected states. DISCUSSION: Due to certain state regulations, a function for disabling the front seat video option has been incorporated into the vehicle. This function will enable or disable the radio's ability to play video in the front seat. If enabled, the radio will play video when the vehicle is in Park (Automatic Transmission) or when the parking brake is set and vehicle speed is zero (Manual Transmission). If disabled the radio will NOT play video in the front seat in any operating mode. If it becomes necessary to disable the front seat video option, use the following procedure. NOTE: Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Entertainment System - Disabling Front Seat Video Source > Page 6362 Using the wiTECH Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP" tab on upper portion of the wiTECH window, then "HELP CONTENTS." This will open the Welcome to wiTECH Help screen were help topics can now selected. 1. Connect the wiTech 2. From the Home Screen select Radio 3. Select "Misc. Functions" 4. Select "Enable/Disable Front Seat Video" 5. Select "Enable" or "Disable" as required by your state laws. 6. Select finish to exit. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations > Page 6366 Garage Door Opener Transmitter: Diagrams Connector - (HEADLINER) 2 WAY MODULE-UGDO - (HEADLINER) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation > Universal Transmitter - Description Garage Door Opener Transmitter: Description and Operation Universal Transmitter - Description DESCRIPTION Some vehicles are equipped with a Universal Transmitter transceiver (4). The universal transmitter transceiver (4) is located in the headliner (5) just to the rear of the courtesy/reading lamps (1). The only visible component of the universal transmitter are the three transmitter push buttons. The three universal transmitter push buttons are identified with raised buttons and contain a transmit indicator that lights during operation and programming functions. Each of the three universal transmitter push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 280 to 435 Mega Hertz (MHz) frequency range for remote operation. The universal transmitter is capable of operating systems using either rolling code or non-rolling code technology. The system will not transmit operating signals if the Vehicle Theft Security System is armed. The universal transmitter cannot be repaired, and if inoperative or damaged, the complete module assembly must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation > Universal Transmitter - Description > Page 6369 Garage Door Opener Transmitter: Description and Operation Universal Transmitter - Operation OPERATION The HomeLink(R) transceiver operates on a non-switched source of battery current so the unit will remain functional, regardless of the ignition switch position. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics Garage Door Opener Transmitter: Component Tests and General Diagnostics UNIVERSAL TRANSMITTER If the Universal Transmitter is inoperative, retrain the universal transmitter with a known good transmitter, insuring the transmitter battery is OK, See: Programming and Relearning for the proper procedure. Test the universal transmitter operation again. If the unit is still inoperative, test the universal transmitter with Radio Frequency Detector special tool as described below: 1. Turn the Radio Frequency (RF) Detector ON (3). A "chirp" will sound and the green power Light Emitting Diode (LED) will light (2). If the green LED does not light, replace the battery (4). 2. Hold the RF detector within 2.5 cm (1 inch) of the TRAINED universal transmitter and press any of the transmitters buttons. 3. The red signal detection LEDs (1) will light and the tool will beep if a radio signal is detected. Repeat this test for all three transmitter buttons. If the tool does not detect a radio signal for any of the three buttons, replace the inoperative universal transmitter assembly, See: Service and Repair/Universal Transmitter - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 6372 Garage Door Opener Transmitter: Programming and Relearning Programming Homelink(R) Transceiver Codes PROGRAMMING HOMELINK(R) TRANSCEIVER CODES Programming Common HomeLink(R) Transmitter Codes WARNING: Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: Your motorized door or gate may open and close while you are training the HomeLink(R) Transceiver if the vehicle is in range of the motorized device. Do not train the HomeLink(R) transceiver if people or pets are in the path of the door or gate. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: When programming a garage door opener, it is advised to park outside the garage. It is also recommended that a new battery be placed in the hand-held transmitter of the device being programmed to HomeLink(R) for quicker training and accurate transmission of the radio-frequency signal. NOTE: If programing the HomeLink(R) transceiver is unsuccessful using the following procedure. - Press and hold the two outer HomeLink(R) buttons, and release only when the indicator light begins to flash (after 20 seconds). Do not hold the buttons for longer than 30 seconds and do not repeat step one to program a second and/or third hand-held transmitter to the remaining two HomeLink(R) buttons. - Position the end of your hand-held transmitter 3-8 cm (1-3 inches) away from the HomeLink(R) buttons while keeping the indicator light in view. - Simultaneously press and hold both the HomeLink(R) buttons that you want to train and the hand-held transmitter button. Do not release the buttons until step 4 has been completed.NOTE: Some gate operators and garage door openers may require you to replace this Programming Step 3 with procedures noted in the "Gate Operator/Canadian Programming". - The HomeLink(R) indicator light will flash slowly and then rapidly after HomeLink(R) successfully receives the frequency signal from the hand-held transmitter. Release both buttons after the indicator light changes from the slow to the rapid flash. - Press and hold the just trained HomeLink(R) button and observe the indicator light. If the indicator light stays on constantly, programming is complete and your device should activate when the HomeLink(R) button is pressed and released. NOTE: To program the remaining two HomeLink(R) buttons, begin with "Programming" step 2. Do not repeat step 1. If the indicator light blinks rapidly for two seconds and then turns to a constant light, continue with "Programming" steps 6-8 to complete the programming of a rolling code equipped device (most commonly a garage door opener). - At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. - Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.)NOTE: There are 30 seconds in which to initiate step 8. - Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink(R) button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. HomeLink(R) should now activate your rolling code equipped device. NOTE: To program the remaining two HomeLink(R) buttons, begin with "Programming" step 2. Do not repeat step 1. Canadian Programming/Gate Programming Canadian radio-frequency laws require transmitter signals to "time-out" (or quit) after several seconds of transmission which may not be long enough for HomeLink(R) to pick up the signal during programming. Similar to this Canadian law, some U.S. gate operators are designed to "time-out" in the same manner. If you live in Canada or you are having difficulties programming a gate operator by using the "Programming" procedures (regardless of where you live), replace "Programming HomeLink(R)" step 3 with the following: NOTE: When programming a garage door opener or gate operator, it is advised to unplug the device or move the vehicle out of range during the "cycling" process to prevent possible overheating. - 3. Continue to press and hold the HomeLink(R) button while you press and release every two seconds ("cycle") your hand-held transmitter until the frequency signal has successfully been accepted by HomeLink(R). (The indicator light will flash slowly and then rapidly.) Proceed with "Programming" step 4 to complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 6373 Reprogramming Homelink(R) Transmitter Codes REPROGRAMMING HOMELINK(R) TRANSMITTER CODES Reprogramming Basic HomeLink(R) Transmitter Codes WARNING: Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the HomeLink(R) transceiver. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: Your motorized door or gate may open and close while you are training the HomeLink(R) Transceiver if the vehicle is in range of the motorized device. Do not train the HomeLink(R) transceiver if people or pets are in the path of the door or gate. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: If programing the HomeLink(R) transceiver is unsuccessful using the following procedure. To program a device to the HomeLink(R) transceiver using a button previously trained, follow these steps: - Press and hold the desired HomeLink(R) transceiver button. DO NOT release the button. The indicator light will begin to flash after 20 seconds. Without releasing the HomeLink(R) transceiver button, proceed to step 2. - Position the end of your hand-held transmitter 3-8 cm (1-3 inches) away from the HomeLink(R) transceiver button while keeping the indicator light in view. - Simultaneously press and hold both the HomeLink(R) transceiver button that you want to train and the hand-held transmitter buttons. Do not release the buttons until step 4 has been completed.NOTE: Some gate operators and garage door openers may require you to replace this Reprogramming Step 3 with procedures noted in the "Gate Operator/Canadian Programming". - The HomeLink(R) transceiver indicator light will flash slowly and then rapidly after it successfully receives the frequency signal from the hand-held transmitter. Release both buttons after the indicator light changes from the slow to the rapid flash. - Press and hold the just trained HomeLink(R) transceiver button and observe the indicator light. If the indicator light stays on constantly, reprogramming is complete and your device should activate when the button is pressed and released. NOTE: If the indicator light blinks rapidly for two seconds and then turns to a constant light, continue with "Reprogramming" steps 6-8 to complete the programming of a rolling code equipped device (most commonly a garage door opener). - At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. - Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.)NOTE: There are 30 seconds in which to initiate step 8. - Return to the vehicle and firmly press, hold for two seconds and release the reprogrammed HomeLink(R) transceiver button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the reprogramming. The HomeLink(R) transceiver should now activate your rolling code equipped device. Canadian Programming/Gate Programming Canadian radio-frequency laws require transmitter signals to "time-out" (or quit) after several seconds of transmission which may not be long enough for HomeLink(R) to pick up the signal during programming. Similar to this Canadian law, some U.S. gate operators are designed to "time-out" in the same manner. If you live in Canada or you are having difficulties programming a gate operator by using the "Programming" procedures (regardless of where you live), replace "Programming HomeLink(R)" step 3 with the following: NOTE: When programming a garage door opener or gate operator, it is advised to unplug the device or move the vehicle out of range during the "cycling" process to prevent possible overheating. - 3. Continue to press and hold the HomeLink(R) button while you press and release every two seconds ("cycle") your hand-held transmitter until the frequency signal has successfully been accepted by HomeLink(R). (The indicator light will flash slowly and then rapidly.) Proceed with "Programming" step 4 to complete. Erasing Transmitter Codes ERASING TRANSMITTER CODES NOTE: Individual channels cannot be erased. Erasing the transmitter codes will erase ALL programmed codes. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 6374 To erase programming from the three buttons (individual buttons cannot be erased but can be "reprogrammed"), follow the step noted: - Press and hold the two outer HomeLink(R) buttons until the indicator light begins to flash after 20 seconds. Release both buttons. Do not hold for longer that 30 seconds. HomeLink(R) is now in the train (or learning) mode and can be programmed at any time beginning with "Programming" . See: Programming Homelink(R) Transceiver Codes Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Universal Transmitter - Removal Garage Door Opener Transmitter: Service and Repair Universal Transmitter - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the courtesy/reading lamp lens (5). Insert a suitable flat bladed tool into the slot (6) in the courtesy/reading lamp assembly (2). Pivot the lens down and to the left to release the holding tab (4). Remove the lamp assembly from the headliner (3). 3. Using an appropriate flat bladed tool, remove the universal transmitter button trim bezel (4). 4. Working through the courtesy/reading lamp hole in the headliner, pull the universal transmitter module (1) forward and down through the headliner (2). 5. Disconnect the electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Universal Transmitter - Removal > Page 6377 6. Remove the universal transmitter module from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Universal Transmitter - Removal > Page 6378 Garage Door Opener Transmitter: Service and Repair Universal Transmitter - Installation INSTALLATION 1. Position the universal transmitter module (1) into the vehicle. 2. Connect the electrical connector (4). 3. Working through the courtesy/reading lamp hole in the headliner (2), insert the universal transmitter module up into place over the cut out for the button bezel (3). 4. Position the universal transmitter module (2) so that the mounting tabs (4) on the button bezel (5) are aligned with the module slots. 5. Holding the module in place push the universal transmitter button bezel through the headliner until the mounting tabs are securely engaged with the module. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Universal Transmitter - Removal > Page 6379 6. Position the courtesy/reading lamp assembly (2) into the headliner (3). 7. Insert the mounting tab (4) on the lamp lens (5) into the right side of the lamp assembly and pivot the lens up until it snaps securely in place. 8. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations Integrated Accessory Switch Assembly: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations > Page 6383 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations > Page 6384 Integrated Accessory Switch Assembly: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY SWITCH-BANK - (INSTRUMENT PANEL) 8 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations > Page 6385 Integrated Accessory Switch Assembly: Description and Operation DESCRIPTION There is an Accessory Switch Bank Module (ASBM) located in the instrument panel center stack just below the heater a/c control. Included in this switch bank are: - Electronic Stability Program (ESP)/Traction Control Switch (TCS) Off (if equipped) - See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Traction Control Switch/Description and Operation - Hazard Switch (all models) - See: Lighting and Horns/Hazard Warning Lamps/Hazard Warning Switch/Description and Operation/Hazard Warning Switch - Description - Heated Seat Switch (if equipped) - See: Body and Frame/Seats/Seat Heater Switch/Description and Operation/Heated Seat Switch - Description - Passenger Airbag Disabled Lamp (PADL) Indicator (if equipped with OCS) - See: Restraint Systems/Description and Operation/Restraints - Description. The BUX version of the ASBM will vary from the domestic a bit. Following are the various BUX switches: - Anti-Skid Control (ASC) (if equipped) - This is the same as the ESP/TCS off switch in the domestic version. - Hazard Switch (all models) - Heated Seat Switch (if equipped) - Headlamp Leveling Switch (if equipped) Each individual switch is not available for service replacement. If one or more switches are inoperative, the entire ASBM must be replaced See: Service and Repair/Instrument Cluster Switch Pod - Removal. To diagnose the ASBM switches, use a scan tool and the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Instrument Cluster Switch Pod - Removal Integrated Accessory Switch Assembly: Service and Repair Instrument Cluster Switch Pod Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the screws to the Accessory Switch Bank Module (ASBM) (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Instrument Cluster Switch Pod - Removal > Page 6388 Integrated Accessory Switch Assembly: Service and Repair Instrument Cluster Switch Pod Installation INSTALLATION 1. Position the Accessory Switch Bank Module (ASBM) (4) in the center bezel. 2. Install the screws to the ASBM. 3. Install the instrument panel center bezel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > Customer Interest for Amplifier: > 08-036-08 > Nov > 08 > Audio System - Software Update For Various Issues Amplifier: Customer Interest Audio System - Software Update For Various Issues NUMBER: 08-036-08 GROUP: Electrical DATE: November 27 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.03 OR HIGHER FOR THIS BULLETIN. StarMOBILE STANDALONE MODE OR StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Audio System Mutes On Start-Up Amplifier Settings After Exiting Hands Free Mode And Navigational Volume Corrections OVERVIEW: This bulletin involves selectively erasing and reprogramming the production Audio Amplifier with new software. MODELS: 2009 (JS) Sebring/Avenger (Domestic and International Markets) 2008 (L2) 300 (China) 2008 (LE) 300C/300 Touring (International Markets) 2008 (LX) 00oC/Magnum/Charger 2009 (MK) Compass/Patriot (Domestic and International Markets) 2009 (PM) Caliber (Domestic and International Markets) 2008 (WK) Grand Cherokee 2008 (WH) Grand Cherokee (International Markets) 2008 (XK) Commander 2008 (XH) Commander (International markets) NOTE: This bulletin applies to vehicles equipped with a Boston Acoustics Audio System (Amplifier Sales Code RC6, RC9, RD7, RDF, and RDM) SYMPTOM/CONDITION: Some customers may experience any one of the following conditions: ^ Audio system mutes on start-up. Mute is recoverable with Ignition key cycle. (XK XH WK WH and W2 models only) ^ The amplifier will not go back to EQ settings after exiting hands tree mode/voice recognition mode. Settings are recoverable by an ignition cycle tone control change and/or a mode change. ^ Navigation volume adjustments change cabin audio and not navigation volume. (RHD vehicles only) DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT verity all systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. It the customer describes or experiences the Symptom/Condition perform the Repair Procedure. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > Customer Interest for Amplifier: > 08-036-08 > Nov > 08 > Audio System - Software Update For Various Issues > Page 6398 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 9.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN® is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter verity that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old Radio Amplifier part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the Radio AMP in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash AMP" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > Customer Interest for Amplifier: > 08-036-08 > Nov > 08 > Audio System - Software Update For Various Issues > Page 6399 g. Select "Download to Scantool". h. Select "Close" after the download is complete then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the update is complete select "OK". 7. Verity the part number at the top of the "Flash AMP" screen has updated to the new part number. NOTE: Due to the Radio Amplifier programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Amplifier: > 08-036-08 > Nov > 08 > Audio System - Software Update For Various Issues Amplifier: All Technical Service Bulletins Audio System - Software Update For Various Issues NUMBER: 08-036-08 GROUP: Electrical DATE: November 27 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.03 OR HIGHER FOR THIS BULLETIN. StarMOBILE STANDALONE MODE OR StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Audio System Mutes On Start-Up Amplifier Settings After Exiting Hands Free Mode And Navigational Volume Corrections OVERVIEW: This bulletin involves selectively erasing and reprogramming the production Audio Amplifier with new software. MODELS: 2009 (JS) Sebring/Avenger (Domestic and International Markets) 2008 (L2) 300 (China) 2008 (LE) 300C/300 Touring (International Markets) 2008 (LX) 00oC/Magnum/Charger 2009 (MK) Compass/Patriot (Domestic and International Markets) 2009 (PM) Caliber (Domestic and International Markets) 2008 (WK) Grand Cherokee 2008 (WH) Grand Cherokee (International Markets) 2008 (XK) Commander 2008 (XH) Commander (International markets) NOTE: This bulletin applies to vehicles equipped with a Boston Acoustics Audio System (Amplifier Sales Code RC6, RC9, RD7, RDF, and RDM) SYMPTOM/CONDITION: Some customers may experience any one of the following conditions: ^ Audio system mutes on start-up. Mute is recoverable with Ignition key cycle. (XK XH WK WH and W2 models only) ^ The amplifier will not go back to EQ settings after exiting hands tree mode/voice recognition mode. Settings are recoverable by an ignition cycle tone control change and/or a mode change. ^ Navigation volume adjustments change cabin audio and not navigation volume. (RHD vehicles only) DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT verity all systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. It the customer describes or experiences the Symptom/Condition perform the Repair Procedure. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Amplifier: > 08-036-08 > Nov > 08 > Audio System - Software Update For Various Issues > Page 6405 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 9.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN® is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter verity that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old Radio Amplifier part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the Radio AMP in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash AMP" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Amplifier: > 08-036-08 > Nov > 08 > Audio System - Software Update For Various Issues > Page 6406 g. Select "Download to Scantool". h. Select "Close" after the download is complete then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". k. When the update is complete select "OK". 7. Verity the part number at the top of the "Flash AMP" screen has updated to the new part number. NOTE: Due to the Radio Amplifier programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > Page 6407 Amplifier: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Technical Service Bulletins > Page 6408 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Radio Amplifier C1 (Body) 20 Way Amplifier: Diagrams Radio Amplifier C1 (Body) 20 Way Connector C1 - (BODY) 20 WAY AMPLIFIER-RADIO - (BODY) 20 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Radio Amplifier C1 (Body) 20 Way > Page 6411 Amplifier: Diagrams Radio Amplifier C2 (Body) 14 Way Connector C2 - (BODY) 14 WAY AMPLIFIER-RADIO - (BODY) 14 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Amplifier - Description Amplifier: Description and Operation Amplifier - Description DESCRIPTION The optional premium speaker system includes a separate audio power amplifier. The amplifier is located on the floor behind the spare tire in the trunk. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Amplifier - Description > Page 6414 Amplifier: Description and Operation Amplifier - Operation OPERATION The power amplifier electronically increases the frequency response of the normal audio signal output from the radio amplifier in order to improve the acoustic performance of the speakers. On vehicles equipped with an amplifier, the amplifier section of the radio becomes a pre-amplifier. The amplifier receives audio signal inputs for speaker channels from the radio, then sends amplified audio outputs with dedicated feed and return circuits to the individual speakers. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Amplifier - Removal Amplifier: Service and Repair Amplifier - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the retaining fasteners. 3. Disconnect the wire harness connector. 4. Remove the amplifier (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Amplifier - Removal > Page 6417 Amplifier: Service and Repair Amplifier - Installation INSTALLATION 1. Install amplifier (1). 2. Install the mounting fasteners. 3. Connect wire harness connector to amplifier. 4. Connect battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Diagrams > Satellite Receiver C1 (SDARS Jumper) 12 Way Radio Receiver: Diagrams Satellite Receiver C1 (SDARS Jumper) 12 Way Connector C1 - (SDARS JUMPER) 12 WAY RECEIVER-SATELLITE - (SDARS JUMPER) 12 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Diagrams > Satellite Receiver C1 (SDARS Jumper) 12 Way > Page 6423 Radio Receiver: Diagrams Satellite Receiver C2 (SDARS Jumper) 2 Way Connector C2 - (SDARS JUMPER) 2 WAY RECEIVER-SATELLITE - (SDARS JUMPER) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Description and Operation > Satellite Receiver Module - Description Radio Receiver: Description and Operation Satellite Receiver Module - Description DESCRIPTION The satellite receiver module is located behind the spare tire. It is mounted to a bracket which is fastened to the trunk floor sheet metal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Description and Operation > Satellite Receiver Module - Description > Page 6426 Radio Receiver: Description and Operation Satellite Receiver Module - Operation OPERATION The satellite receiver module receives signals from the roof mounted antenna and processes this information before it is sent to the radio. The module operates on both battery and accessory feed circuits and will operate with the ignition key in the RUN or ACCESSORY position only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Service and Repair > Satellite Receiver Module - Removal Radio Receiver: Service and Repair Satellite Receiver Module - Removal REMOVAL NOTE: If the owner's satellite service was active before the satellite receiver module was replaced the new satellite receiver module will have to be activated. The existing satellite receiver module will have to be deactivated before the replacement satellite receiver module can be activated. To activate Sirius satellite radio service, call Sirius at their toll-free number. Please have the following information available when activating a system: - Electronic Serial Number / Sirius Identification Number (ESN/SID) of the unit to be replaced - ESN/SID of the replacement receiver - Vehicle Owner's name and address - VIN The ESN/SID number can be obtained through the radio display by following the steps in the satellite radio owners manual. The vehicle must be outside with the audio system powered on, in the satellite radio mode, to receive the activation signal. 1. Disconnect and isolate the battery negative cable. 2. Remove the left rear quarter trim panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Remove the mounting bracket fasteners. 4. Disconnect the wire harness connectors. 5. Remove the module from the mounting bracket. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Service and Repair > Satellite Receiver Module - Removal > Page 6429 Radio Receiver: Service and Repair Satellite Receiver Module - Installation INSTALLATION NOTE: If the owner's satellite service was active before the satellite receiver module was replaced the new satellite receiver module will have to be activated. The existing satellite receiver module will have to be deactivated before the replacement satellite receiver module can be activated. To activate Sirius satellite radio service, call Sirius at their toll-free number. Please have the following information available when activating a system: - Electronic Serial Number / Sirius Identification Number (ESN/SID) of the unit to be replaced - ESN/SID of the replacement receiver - Vehicle Owner's name and address - VIN The ESN/SID number can be obtained through the radio display by following the steps in the satellite radio owners manual. The vehicle must be outside with the audio system powered on, in the satellite radio mode, to receive the activation signal. 1. Position the module to the mounting bracket. 2. Connect wire harness connectors. 3. Install mounting bracket and fasteners. 4. Install the left rear quarter trim panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 5. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Description and Operation > Radio Noise Suppression - Description Radio/Stereo Noise Filter: Description and Operation Radio Noise Suppression - Description DESCRIPTION Radio noise suppression devices are factory-installed standard equipment on this vehicle. Radio Frequency Interference (RFI) and Electro Magnetic Interference (EMI) can be produced by any on-board or external source of electromagnetic energy. These electromagnetic energy sources can radiate electromagnetic signals through the air, or conduct them through the vehicle electrical system. When the audio system converts RFI or EMI to an audible acoustic wave form, it is referred to as radio noise. This undesirable radio noise is generally manifested in the form of "buzzing," "hissing," "popping," "clicking," "crackling," and/or "whirring" sounds. In most cases, RFI and EMI radio noise can be suppressed using a combination of vehicle and component grounding, filtering and shielding techniques. This vehicle is equipped with factory-installed radio noise suppression devices that were designed to minimize exposure to typical sources of RFI and EMI; thereby, minimizing radio noise complaints. Radio noise suppression is accomplished primarily through circuitry or devices that are integral to the radios, audio power amplifiers and other on-board electrical components such as generators, wiper motors, blower motors, and fuel pumps that have been found to be potential sources of RFI or EMI. External radio noise suppression devices that are used on this vehicle to control RFI or EMI, and can be serviced, include the following: Ground straps - This length of braided ground strap has an eyelet terminal connector crimped to each end. They are located in various locations on the vehicle. - Radio Noise Suppression Capacitor - This component is attached near the exhaust manifold. - Resistor-type spark plugs - This type of spark plug has an internal resistor connected in series between the spark plug terminal and the center electrode to help reduce the production of electromagnetic radiation that can result in radio noise. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Description and Operation > Radio Noise Suppression - Description > Page 6434 Radio/Stereo Noise Filter: Description and Operation Radio Noise Suppression - Operation OPERATION There are two common strategies that can be used to suppress Radio Frequency Interference (RFI) and Electro Magnetic Interference (EMI) radio noise. The first suppression strategy involves preventing the production of RFI and EMI electromagnetic signals at their sources. The second suppression strategy involves preventing the reception of RFI and EMI electromagnetic signals by the audio system components. The use of braided ground straps in key locations is part of the RFI and EMI prevention strategy. These ground straps ensure adequate ground paths, particularly for high current components such as many of those found in the starting, charging, ignition, engine control and transmission control systems. An insufficient ground path for any of these high current components may result in radio noise caused by induced voltages created as the high current seeks alternative ground paths through components or circuits intended for use by, or in close proximity to the audio system components or circuits. Preventing the reception of RFI and EMI is accomplished by ensuring that the audio system components are correctly installed in the vehicle. Loose, corroded or improperly soldered wire harness connections, improperly routed wiring and inadequate audio system component grounding can all contribute to the reception of RFI and EMI. A properly grounded antenna body and radio chassis, as well as a shielded antenna coaxial cable with clean and tight connections will each help reduce the potential for reception of RFI and EMI. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Radio Noise Suppression - Removal Radio/Stereo Noise Filter: Service and Repair Radio Noise Suppression - Removal REMOVAL ENGINE GROUND STRAP 1. Disconnect and isolate the battery negative cable. 2. For the 1.6L Engine, remove bolt from engine cylinder head. 3. For the 2.0/2.4L Engine, remove bolt from engine cylinder head. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Radio Noise Suppression - Removal > Page 6437 4. For the 2.2L Engine, remove bolt from engine cylinder head. 5. Remove bolt from strut tower and remove strap. HOOD HINGE GROUND STRAP 1. Disconnect and isolate the battery negative cable. 2. Remove bolt from fender. 3. Remove bolt from hood and remove strap. MUFFLER GROUND STRAP Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Radio Noise Suppression - Removal > Page 6438 1. Disconnect and isolate the battery negative cable. 2. Remove bolt from rear floor pan. 3. Remove bolt from muffler and remove strap. RADIO NOISE SUPPRESSION CAPACITOR 1. Disconnect and isolate the battery negative cable. 2. Disconnect electrical harness connector from capacitor (1). 3. Remove bolt from capacitor and remove capacitor. STRUT BRACKET TO BODY GROUND STRAP 1. Disconnect and isolate the battery negative cable. 2. Remove bolt from strut. 3. Remove strap from frame rail. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Radio Noise Suppression - Removal > Page 6439 Radio/Stereo Noise Filter: Service and Repair Radio Noise Suppression - Installation INSTALLATION ENGINE GROUND STRAP 1. Install strap and bolt to strut tower. Tighten bolt to 12 Nm (106 in. lbs.). 2. Install strap and bolt to engine cylinder head. Tighten bolt to 28 Nm (21 ft. lbs.). 3. Connect battery negative cable. HOOD HINGE GROUND STRAP 1. Install strap and bolt to fender. Tighten bolt to 4 Nm (35 in. lbs.). 2. Install strap and bolt to hood. Tighten bolt to 4 Nm (35 in. lbs.). 3. Connect battery negative cable. MUFFLER GROUND STRAP Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Radio Noise Suppression - Removal > Page 6440 1. Install strap and bolt to rear floor pan. Tighten bolt to 8 Nm (71 in. lbs.). 2. Install strap and bolt to muffler. Tighten bolt to 8 Nm (71 in. lbs.). 3. Connect battery negative cable. RADIO NOISE SUPPRESSION CAPACITOR 1. Install capacitor and bolt. 2. Connect electrical harness connector to capacitor. 3. Connect battery negative cable. STRUT BRACKET TO BODY GROUND STRAP 1. Install strap to frame rail. CAUTION: Ensure that ground strap does not come in contact with brake hose. Damage to brake hose can result. 2. Install strap and bolt to strut. Tighten bolt to 12 Nm (106 in. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Radio Noise Suppression - Removal > Page 6441 3. Connect battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way Remote Switch: Diagrams Left Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-LEFT - (STEERING WHEEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way > Page 6447 Remote Switch: Diagrams Right Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-RIGHT - (STEERING WHEEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Remote Radio Switches Description Remote Switch: Description and Operation Remote Radio Switches - Description DESCRIPTION Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Remote Radio Switches Description > Page 6450 Remote Switch: Description and Operation Remote Radio Switches - Operation OPERATION These switches are resistor multiplexed units that are hard-wired to the Cab Compartment Node (CCN) through the clockspring. The CCN sends the proper messages on the Controller Area Network (CAN) data bus network to the radio receiver. For diagnosis of the CCN or the CAN data bus, the use of a scan tool and the proper Diagnostic Procedures manual are recommended. For more information on the operation of the remote radio switch controls, refer to the owner's manual in the vehicle glove box. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 6451 Remote Switch: Testing and Inspection REMOTE SWITCHES WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. Any diagnosis of the Audio system should begin with the use of the scan tool. For complete circuit diagrams, refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. See: Service and Repair/Remote Radio Switches - Removal. 3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test table REMOTE RADIO SWITCH TEST NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in driver's seat. 4. If the switch resistance checks OK, go to 5. If not OK, replace the faulty switch. 5. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity. If OK, go to 6. If not OK, repair the open circuit as required. 6. Unplug the connector from the Cab Compartment Node (CCN). Check for continuity between the radio control circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to 7. If not OK, repair the short circuit as required. 7. Check for continuity between the radio control circuit cavities of the remote radio switch wire harness connector and the CCN wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the CCN and the CAN data bus. If not OK, repair the open circuit as required. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches - Removal Remote Switch: Service and Repair Remote Radio Switches - Removal REMOVAL WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Removal. 3. Remove the steering wheel See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Removal. 4. Unplug the wire harness connector from the remote radio switch. 5. Remove steering wheel rear cover. 6. Remove the remote radio switch from the steering wheel by depressing tabs on each side of each switch. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in driver's seat. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches - Removal > Page 6454 Remote Switch: Service and Repair Remote Radio Switches - Installation INSTALLATION WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Install remote radio switch to the steering wheel. 2. Install steering wheel rear cover. 3. Connect the wire harness to the remote radio switch. 4. Install the steering wheel See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Installation. 5. Install the driver side airbag See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Installation. 6. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Liftgate Speaker Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Liftgate Speaker > Page 6459 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Liftgate Speaker > Page 6460 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Liftgate Speaker > Page 6461 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Front Door Speaker (Left Front Door) 3 Way Speaker: Diagrams Left Front Door Speaker (Left Front Door) 3 Way Connector - (LEFT FRONT DOOR) 3 WAY SPEAKER-LEFT FRONT DOOR - (LEFT FRONT DOOR) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Front Door Speaker (Left Front Door) 3 Way > Page 6464 Speaker: Diagrams Left Front Door Speaker (Left Rear Door) 3 Way Connector - (LEFT REAR DOOR) 3 WAY SPEAKER-LEFT FRONT DOOR - (LEFT REAR DOOR) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Front Door Speaker (Left Front Door) 3 Way > Page 6465 Speaker: Diagrams Left Front Door Speaker (Premium) (Instrument Panel) 2 Way Connector (PREMIUM) - (INSTRUMENT PANEL) 2 WAY SPEAKER-LEFT FRONT DOOR (PREMIUM) - (INSTRUMENT PANEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Front Door Speaker (Left Front Door) 3 Way > Page 6466 Speaker: Diagrams Liftgate Speaker (Except Base) (Liftgate) 4 Way Connector (EXCEPT BASE) - (LIFTGATE) 4 WAY SPEAKER-LIFTGATE (EXCEPT BASE) - (LIFTGATE) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Front Door Speaker (Left Front Door) 3 Way > Page 6467 Speaker: Diagrams Left Front Door Speaker (Left Front Door) 3 Way Connector - (LEFT FRONT DOOR) 3 WAY SPEAKER-LEFT FRONT DOOR - (LEFT FRONT DOOR) 3 WAY Left Front Door Speaker (Left Rear Door) 3 Way Connector - (LEFT REAR DOOR) 3 WAY SPEAKER-LEFT FRONT DOOR - (LEFT REAR DOOR) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Front Door Speaker (Left Front Door) 3 Way > Page 6468 Left Front Door Speaker (Premium) (Instrument Panel) 2 Way Connector (PREMIUM) - (INSTRUMENT PANEL) 2 WAY SPEAKER-LEFT FRONT DOOR (PREMIUM) - (INSTRUMENT PANEL) 2 WAY Liftgate Speaker (Except Base) (Liftgate) 4 Way Connector (EXCEPT BASE) - (LIFTGATE) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Front Door Speaker (Left Front Door) 3 Way > Page 6469 SPEAKER-LIFTGATE (EXCEPT BASE) - (LIFTGATE) 4 WAY Right Front Door Speaker (Premium) (Instrument Panel) 2 Way Connector (PREMIUM) - (INSTRUMENT PANEL) 2 WAY SPEAKER-RIGHT FRONT DOOR (PREMIUM) - (INSTRUMENT PANEL) 2 WAY Right Front Door Speaker (Right Front Door) 3 Way Connector - (RIGHT FRONT DOOR) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Front Door Speaker (Left Front Door) 3 Way > Page 6470 SPEAKER-RIGHT FRONT DOOR - (RIGHT FRONT DOOR) 3 WAY Right Front Door Speaker (Right Rear Door) 3 Way Connector - (RIGHT REAR DOOR) 3 WAY SPEAKER-RIGHT FRONT DOOR - (RIGHT REAR DOOR) 3 WAY Subwoofer Speaker (Premium) (Body) 10 Way Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Front Door Speaker (Left Front Door) 3 Way > Page 6471 Connector (PREMIUM) - (BODY) 10 WAY SPEAKER-SUBWOOFER (PREMIUM) - (BODY) 10 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker - Removal Speaker: Service and Repair Speaker - Removal REMOVAL DOOR SPEAKERS 1. Using an approved flat blade tool find the service notch located at the bottom of speaker grille and pry up speaker grille. 2. Remove the four screws attaching the speaker (2) to door panel (3). 3. Disconnect the electrical connector and remove the speaker. INSTRUMENT PANEL SPEAKER Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker - Removal > Page 6474 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel (2) top cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Removal. 3. Remove speaker retaining screws. 4. Remove speaker (1) and disconnect wire harness connector. REAR SPEAKER - LIFTGATE 1. Disconnect and isolate the battery negative cable. 2. Remove the speaker enclosure fasteners. 3. Remove speaker and disconnect the electrical harness connector. REAR SUBWOOFER Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker - Removal > Page 6475 1. Disconnect and isolate the battery negative cable. 2. Remove the right quarter trim panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Remove the subwoofer mounting fasteners. 4. Disconnect the electrical harness connector. 5. Remove the speaker. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker - Removal > Page 6476 Speaker: Service and Repair Speaker - Installation INSTALLATION DOOR SPEAKERS 1. Connect wire connector. 2. Install speaker (2) into the door panel (3) opening and install the four screws into door panel. 3. Install speaker grille (1) onto trim panel. INSTRUMENT PANEL SPEAKER 1. Connect wire harness connector to speaker (1). 2. Install speaker screws. 3. Install instrument panel (2) top cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Installation. 4. Connect the battery negative cable. REAR SPEAKER - TAILGATE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker - Removal > Page 6477 1. Connect electrical harness connector and position speaker. 2. Install and tighten mounting fasteners. 3. Connect battery negative cable. REAR SUBWOOFER 1. Position the speaker and connect the electrical harness connector. 2. Install the subwoofer mounting fasteners. 3. Install the right rear quarter trim panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Sentry Key Immobilizer Module (SKREEM) - Description Alarm Module: Description and Operation Sentry Key Immobilizer Module (SKREEM) - Description DESCRIPTION When a PCM and the SKREEM are replaced at the same time, perform the following steps in order: 1. Program the new PCM. 2. Program the new SKREEM. 3. Replace all ignition keys and program them to the new SKREEM.See: Keyless Entry Module/Testing and Inspection/Programming and Relearning The Sentry Key REmote Entry Module (SKREEM) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM/WCM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system and the Tire Pressure Monitor (TPM) system. The SKREEM/WCM is located on the steering column, around the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM/WCM has an integral molded plastic halo-like antenna ring (3) that extends from one side. When the SKREEM/WCM is properly installed, the antenna ring is oriented around the ignition lock cylinder housing. A single connector (4) is located next to the antenna ring on the SKREEM/WCM housing (3). A molded plastic mounting tab (2) on the SKREEM/WCM housing secures the unit to the steering column. The SKREEM/WCM is connected to the vehicle electrical system through the instrument panel wire harness. The SKREEM/WCM cannot be adjusted or repaired. If faulty or damaged, the entire SKREEM unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Sentry Key Immobilizer Module (SKREEM) - Description > Page 6483 Alarm Module: Description and Operation Sentry Key Immobilizer Module (SKREEM) - Operation OPERATION The Sentry Key REmote Entry Module (SKREEM), sometimes referred to as the Wireless Control Module (WCM), contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM/WCM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM/WCM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM/WCM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver and, if the vehicle is so equipped, the receiver for the Tire Pressure Monitoring (TPM) system. See: Body and Frame/Locks/Power Locks/Description and Operation/Power Locks - Description or See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Description and Operation/Tire Pressure Monitoring (TPM) - Description. The SKREEM/WCM communicates over the Controller Area Network (CAN) data bus with the Electro Mechanical Instrument Cluster (EMIC) (sometimes referred to as the Cab Compartment Node (CCN), the Powertrain Control Module (PCM), and/or the diagnostic scan tool. The SKREEM/WCM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM/WCM. For added system security, each SKREEM/WCM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM/WCM. Therefore, the Secret Key code is a common element that is found in every component of the Sentry Key Immobilizer System (SKIS). Another security code, called a PIN, is used to gain access to the SKREEM/WCM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. See: Antitheft and Alarm Systems/Service and Repair See: Antitheft and Alarm Systems/Alarm System Transponder/Testing and Inspection The SKREEM/WCM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM during SKIS initialization. NOTE: After a SKREEM/WCM is replaced, the ignition/transponder keys need to be programmed to the new SKREEM/WCM. Follow the directions on the diagnostic scan tool. The transponder key for the SKREES/SKIM and the RKE will both be programmed during this operation. There is no need to program the fob of the key for RKE functionality once the transponder key is programmed to the new SKREEM/WCM. In the event that a SKREEM/WCM replacement is required, the Secret Key code can be transferred to the new SKREEM/WCM from the PCM using the diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM/WCM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM/WCM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On position, the SKREEM/WCM transmits an RF signal to the transponder in the ignition key. The SKREEM/WCM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM/WCM sends a valid key message to the PCM over the CAN data bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM/WCM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKREEM/WCM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKREEM/WCM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM/WCM also sends security indicator status messages to the EMIC/CCN over the CAN data bus to tell the EMIC/CCN how to operate the security indicator. The security indicator status message from the SKREEM/WCM tells the EMIC/CCN to turn the indicator on for about three seconds each time the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKREEM/WCM sends security indicator status messages to the EMIC/CCN to turn the indicator off, turn the indicator on, or to flash the indicator on and off. If the security indicator flashes or stays on solid after the bulb test, it signifies a SKIS fault. If the SKREEM/WCM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKREEM/WCM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM/WCM will also send messages to the EMIC/CCN to flash the security indicator whenever the Customer Learn programming mode is being utilized . See: Antitheft and Alarm Systems/Alarm System Transponder/Testing and Inspection The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM/WCM memory if a system malfunction is detected. The SKREEM/WCM can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal Alarm Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Removal REMOVAL NOTE: The steering wheel does not have to be removed to service the SKREEM/WCM. NOTE: The Steering Column Control Module (SCCM) assembly, which consists of the left/right multi-function switches and the clockspring, does not have to be removed to service the SKREEM/WCM. There is an access hole in the top of the right multi-function switch to access the mounting screw (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the upper and lower steering column shrouds See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the SKREEM/WCM mounting screw (2) on the ignition lock assembly and separate the SKREEM/WCM (3) from the ignition lock assembly. 4. Disconnect the SKREEM/WCM electrical connector (4). 5. Remove SKREEM/WCM (1 and 3) from column (2). When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Keyless Entry Module/Testing and Inspection/Programming and Relearning. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 6486 - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 6487 Alarm Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Installation INSTALLATION When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Keyless Entry Module/Testing and Inspection/Programming and Relearning. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. 1. Position the SKREEM/WCM (3) on the ignition lock housing and install the retaining screw (2). 2. Connect the SKREEM/WCM electrical connector (4). NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated . See: Antitheft and Alarm Systems/Alarm System Transponder/Testing and Inspection 3. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 6491 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY MODULE-SENTRY KEY REMOTE ENTRY/WCM - (INSTRUMENT PANEL) 8 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Keyless Entry Module: Initial Inspection and Diagnostic Overview REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic information. Refer to the appropriate wiring information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6494 Keyless Entry Module: Programming and Relearning SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6495 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal Keyless Entry Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Removal REMOVAL NOTE: The steering wheel does not have to be removed to service the SKREEM/WCM. NOTE: The Steering Column Control Module (SCCM) assembly, which consists of the left/right multi-function switches and the clockspring, does not have to be removed to service the SKREEM/WCM. There is an access hole in the top of the right multi-function switch to access the mounting screw (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the upper and lower steering column shrouds See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the SKREEM/WCM mounting screw (2) on the ignition lock assembly and separate the SKREEM/WCM (3) from the ignition lock assembly. 4. Disconnect the SKREEM/WCM electrical connector (4). 5. Remove SKREEM/WCM (1 and 3) from column (2). When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Testing and Inspection/Programming and Relearning. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 6498 - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 6499 Keyless Entry Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Installation INSTALLATION When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Testing and Inspection/Programming and Relearning. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. 1. Position the SKREEM/WCM (3) on the ignition lock housing and install the retaining screw (2). 2. Connect the SKREEM/WCM electrical connector (4). NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated . See: Antitheft and Alarm Systems/Alarm System Transponder/Testing and Inspection 3. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations Voice Activation Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 6503 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 6504 Voice Activation Module: Diagrams Connector - (INSTRUMENT PANEL) 22 WAY MODULE-HANDS FREE - (INSTRUMENT PANEL) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations Integrated Accessory Switch Assembly: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations > Page 6512 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations > Page 6513 Integrated Accessory Switch Assembly: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY SWITCH-BANK - (INSTRUMENT PANEL) 8 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Locations > Page 6514 Integrated Accessory Switch Assembly: Description and Operation DESCRIPTION There is an Accessory Switch Bank Module (ASBM) located in the instrument panel center stack just below the heater a/c control. Included in this switch bank are: - Electronic Stability Program (ESP)/Traction Control Switch (TCS) Off (if equipped) - See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Traction Control Switch/Description and Operation - Hazard Switch (all models) - See: Lighting and Horns/Hazard Warning Lamps/Hazard Warning Switch/Description and Operation/Hazard Warning Switch - Description - Heated Seat Switch (if equipped) - See: Body and Frame/Seats/Seat Heater Switch/Description and Operation/Heated Seat Switch - Description - Passenger Airbag Disabled Lamp (PADL) Indicator (if equipped with OCS) - See: Restraint Systems/Description and Operation/Restraints - Description. The BUX version of the ASBM will vary from the domestic a bit. Following are the various BUX switches: - Anti-Skid Control (ASC) (if equipped) - This is the same as the ESP/TCS off switch in the domestic version. - Hazard Switch (all models) - Heated Seat Switch (if equipped) - Headlamp Leveling Switch (if equipped) Each individual switch is not available for service replacement. If one or more switches are inoperative, the entire ASBM must be replaced See: Service and Repair/Instrument Cluster Switch Pod - Removal. To diagnose the ASBM switches, use a scan tool and the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Instrument Cluster Switch Pod - Removal Integrated Accessory Switch Assembly: Service and Repair Instrument Cluster Switch Pod Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the screws to the Accessory Switch Bank Module (ASBM) (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Integrated Accessory Switch Assembly > Component Information > Service and Repair > Instrument Cluster Switch Pod - Removal > Page 6517 Integrated Accessory Switch Assembly: Service and Repair Instrument Cluster Switch Pod Installation INSTALLATION 1. Position the Accessory Switch Bank Module (ASBM) (4) in the center bezel. 2. Install the screws to the ASBM. 3. Install the instrument panel center bezel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way Remote Switch: Diagrams Left Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-LEFT - (STEERING WHEEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way > Page 6523 Remote Switch: Diagrams Right Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-RIGHT - (STEERING WHEEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Remote Radio Switches - Description Remote Switch: Description and Operation Remote Radio Switches - Description DESCRIPTION Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Remote Radio Switches - Description > Page 6526 Remote Switch: Description and Operation Remote Radio Switches - Operation OPERATION These switches are resistor multiplexed units that are hard-wired to the Cab Compartment Node (CCN) through the clockspring. The CCN sends the proper messages on the Controller Area Network (CAN) data bus network to the radio receiver. For diagnosis of the CCN or the CAN data bus, the use of a scan tool and the proper Diagnostic Procedures manual are recommended. For more information on the operation of the remote radio switch controls, refer to the owner's manual in the vehicle glove box. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 6527 Remote Switch: Testing and Inspection REMOTE SWITCHES WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. Any diagnosis of the Audio system should begin with the use of the scan tool. For complete circuit diagrams, refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. See: Service and Repair/Remote Radio Switches - Removal. 3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test table REMOTE RADIO SWITCH TEST NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in driver's seat. 4. If the switch resistance checks OK, go to 5. If not OK, replace the faulty switch. 5. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity. If OK, go to 6. If not OK, repair the open circuit as required. 6. Unplug the connector from the Cab Compartment Node (CCN). Check for continuity between the radio control circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to 7. If not OK, repair the short circuit as required. 7. Check for continuity between the radio control circuit cavities of the remote radio switch wire harness connector and the CCN wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the CCN and the CAN data bus. If not OK, repair the open circuit as required. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches Removal Remote Switch: Service and Repair Remote Radio Switches - Removal REMOVAL WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Removal. 3. Remove the steering wheel See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Removal. 4. Unplug the wire harness connector from the remote radio switch. 5. Remove steering wheel rear cover. 6. Remove the remote radio switch from the steering wheel by depressing tabs on each side of each switch. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in driver's seat. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches Removal > Page 6530 Remote Switch: Service and Repair Remote Radio Switches - Installation INSTALLATION WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. Install remote radio switch to the steering wheel. 2. Install steering wheel rear cover. 3. Connect the wire harness to the remote radio switch. 4. Install the steering wheel See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Installation. 5. Install the driver side airbag See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Installation. 6. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations Steering Mounted Controls Communication Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Locations > Page 6534 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C1 (Instrument Panel) 4 Way Steering Mounted Controls Communication Module: Diagrams Steering Control Module C1 (Instrument Panel) 4 Way Connector C1 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C1 (Instrument Panel) 4 Way > Page 6537 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C2 (Instrument Panel) 6 Way Connector C2 - (INSTRUMENT PANEL) 6 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Diagrams > Steering Control Module C1 (Instrument Panel) 4 Way > Page 6538 Steering Mounted Controls Communication Module: Diagrams Steering Control Module C4 (Instrument Panel) 4 Way Connector C4 - (INSTRUMENT PANEL) 4 WAY MODULE-STEERING CONTROL - (INSTRUMENT PANEL) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation/Communication - Description. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 6541 Steering Mounted Controls Communication Module: Description and Operation Steering Column Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 6542 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Description DESCRIPTION This vehicle is equipped with a Steering Column Control Module (SCCM) The SCCM is secured near the top of the steering column below the steering wheel and is completely concealed beneath the steering column shrouds. It is installed as a modular unit that supports the left (lighting) multi-function switch (1) and right (wiper) multi-function switch (6). The controls for each of these switches extend through appropriate clearance holes provided in the steering column shrouds. The microprocessor-based Steering Control Module (SCM) (2) utilizes integrated circuitry and information carried on the Controller Area Network (CAN) data bus along with several hard wired analog and multiplexed inputs to monitor both the right and left multi-function switches. The SCCM uses a Local Interconnect Network (LIN) data bus for exterior lighting and wiper functions. The LIN data is sent to the Cab Compartment Node (CCN) and the CCN then sends it out on the CAN data bus See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation/Communication - Description. The SCCM is available for service replacement as a unit or each individual component: - Clockspring (with integral Steering Angle Sensor if equipped) - Left Multi-Function Switch - Right Multi-Function Switch Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Description and Operation > Steering Column Module - Description > Page 6543 Steering Mounted Controls Communication Module: Description and Operation Steering Column Control Module - Operation OPERATION The Steering Control Module (SCM) communicates over the Local Interconnect Network (LIN) data bus with other electronic modules in the vehicle and/or a diagnostic scan tool. The horn switch circuits pass through the clockspring to the Cab Compartment Node (CCN) and the CCN sends a CAN message to the Totally Integrated Power Module (TIPM) to control the horn. The CCN stores Diagnostic Trouble Codes (DTC's) for the SCM. The right (wiper) multi-function switch has several inputs to the CCN. The SCM is connected to a fused B(+) circuit and receives a path to ground at all times. These connections allow it to remain functional regardless of the ignition switch position. The driver airbag squib circuits of the clockspring, the horn, and the speed control switch circuits pass through the SCM, but the SCM does not monitor, and has no control outputs related to these circuits. Any other input to the SCM that would cause a vehicle system to function but does not require that the ignition switch be in the On position, such as turning on the lights or sounding the horn, prompts the SCM to wake up and transmit on the CAN data bus. The most reliable, efficient, and accurate means to diagnose the SCM, the CAN data bus, the hard wired inputs or the electronic communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. The integral SCM is not available for separate service replacement. If found inoperative or defective, the entire left (lighting) multi-function switch must be replaced See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Left Multifunction Switch - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. SCCM 1. Place the front road wheels in the STRAIGHT-AHEAD position. 2. Disconnect and isolate the negative battery cable. 3. Remove steering wheel See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Removal. 4. Remove upper and lower steering column shrouds to gain access to the Steering Column Control Module (SCCM) (3) See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 5. Lock the clockspring rotor in the center position as follows: Insert a pin through the hole in the rotor at the 10 o'clock position. 6. Remove the three screws (1) to the SCCM. 7. Disconnect the electrical connectors (2) between the SCCM (1) and the instrument panel wiring harness at the base of the SCCM and remove from column. DISASSEMBLY NOTE: There is no need to disassemble the Steering Column Control Module (SCCM) if only removing the SCCM from the column. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 6546 1. Remove the left multi-function switch stalk retaining screw (2). 2. Pull the left stalk out of the SCCM. 3. Disconnect the left stalk electrical connector. 4. Separate the left switch from the SCCM. 5. Remove the one right multi-function switch retaining screw. 6. Pull right switch out of SCCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 6547 7. Disconnect the right switch electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 6548 Steering Mounted Controls Communication Module: Service and Repair Steering Column Control Module - Installation INSTALLATION NOTE: If SCCM is already assembled and needs to be installed, bypass ASSEMBLY and proceed with SCCM 1. ASSEMBLY 1. Connect the right stalk electrical connector. 2. Slide the right stalk into the groove and install the one retaining screw. 3. Connect the left stalk switch electrical connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 6549 4. Install the left stalk switch retaining screw. SCCM 1. Position the SCCM (3) over the steering column shaft (2). 2. Install the three screws (1). 3. Connect the electrical connectors (2) to the instrument panel harness, ensure wiring is properly routed. Then check that the connectors, locking tabs are properly engaged. 4. Install steering column shrouds See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. Be sure all wires are inside of shrouds. 5. Install steering wheel ensuring the flats on hub align with the clockspring See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Installation. Pull the airbag leads through the larger slot. Ensure leads do not get pinched under the steering wheel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Communication Module > Component Information > Service and Repair > Steering Column Control Module - Removal > Page 6550 NOTE: There is a small wire harness in the steering wheel and it contains the horn circuits and speed control circuits. 6. Connect the speed control and horn wire connector into the clockspring. 7. Pull the grenade pin out of the clockspring. 8. Install the driver airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Installation WARNING: Do not connect the negative battery cable at this time. Perform the Air Bag System Test prior to connecting the negative battery cable See: Restraint Systems/Testing and Inspection . Failure to follow this warning may result in accidental air bag deployment and possible serious or fatal injury. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Trailer Towing Towing Information: Service and Repair Trailer Towing SPECIFICATIONS - TOWING, Trailer - NAFTA In this article, you will find safety tips and information on limits to the type of towing you can reasonably do with your vehicle. Before towing a trailer carefully review this information to tow your load as efficiently and safely as possible. To maintain warranty coverage, follow the requirements and recommendations concerning vehicles used for trailer towing. Common Towing Definitions The following trailer towing related definitions assists you in understanding the following information: Gross Vehicle Weight Rating (GVWR) The GVWR is the total allowable weight of your vehicle. This includes driver, passengers, cargo and tongue weight. The total load must be limited so that you do not exceed the GVWR. Gross Trailer Weight (GTW) The Gross Trailer Weight (GTW) is the weight of the trailer plus the weight of all cargo, consumables and equipment (permanent or temporary) loaded in or on the trailer in its "loaded and ready for operation" condition. The recommended way to measure GTW is to put your fully loaded trailer on a vehicle scale. The entire weight of the trailer must be supported by the scale. Gross Combination Weight Rating (GCWR) The Gross Combination Weight Rating (GCWR) is the total permissible weight of your vehicle and trailer when weighed in combination. (Note that GCWR ratings include a 68 kg (150 lbs) allowance for the presence of a driver). Gross Axle Weight Rating (GAWR) The GAWR is the maximum capacity of the front and rear axles. Distribute the load over the front and rear axles evenly. Make sure that you do not exceed either the front or rear GAWR. WARNING: It is important that you do not exceed the maximum front or rear GAWR. A dangerous driving condition can result if either rating is exceeded. Failure to follow these instructions may result in serious or fatal injury. Tongue Weight (TW) The tongue weight is the downward force exerted on the hitch ball by the trailer. In most cases it should not be less than 10% or more than 15% of the trailer load. You must consider this as part of the load on your vehicle. Frontal Area The frontal area is the maximum height and maximum width of the front of a trailer. Trailer Sway Control The trailer sway control is a telescoping link that can be installed between the hitch receiver and the trailer tongue that typically provides adjustable friction associated with the telescoping motion to dampen any unwanted trailer swaying motions while traveling. Weight-Carrying Hitch A weight-carrying hitch supports the trailer tongue weight, just as if it were luggage located at a hitch ball or some other connecting point of the truck. These kind of hitches are the most popular on the market today and they're commonly used to tow small- and medium-sized trailers. Weight-Distributing Hitch Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Trailer Towing > Page 6556 Weight Distributing Hitch System A weight-distributing system works by applying leverage through spring (load) bars. They are typically used for heavier loads, to distribute trailer tongue weight to the tow vehicle's front axle and the trailer axle(s). When used in accordance with the manufacturers' directions, it provides for a more level ride, offering more consistent steering and brake control thereby enhancing towing safety. The addition of a friction / hydraulic sway control also dampens sway caused by traffic and crosswinds and contributes positively to tow vehicle and trailer stability. Trailer sway control and a weight distributing (load equalizing) hitch are recommended for heavier Tongue Weights (TW) and may be required depending on Vehicle and Trailer configuration / loading to comply with gross axle weight rating (GAWR) requirements. Improper Adjustment of Weight Distributing System WARNING: An improperly adjusted Weight Distributing Hitch system may reduce handling, stability, braking performance, and could result in an accident. Weight Distributing Systems may not be compatible with Surge Brake Couplers. Consult with your hitch and trailer manufacturer or a reputable Recreational Vehicle dealer for additional information. Failure to follow these instructions may result in possible serious or fatal injury. Installing A Trailer Hitch NOTE: If you install a trailer hitch after you purchase the vehicle, you must install a Mopar (R) spare tire hold down kit. The kit allows you to properly secure the spare tire and jack assembly. WARNING: Do not operate the vehicle without a properly secured tire and jack assembly. Any loose items may be thrown forward in a collision or hard stop and strike occupants. Failure to follow these instructions may result in possible serious or fatal injury. Trailer Hitch Classification The following chart provides the industry standard for the maximum trailer weight a given trailer hitch class can tow and should be used to assist you in selecting the correct trailer hitch for your intended towing condition. Refer to the Trailer Towing Weights (Maximum Trailer Weight Ratings) chart for the Maximum GTW towable for your given drivetrain. All trailer hitches should be professionally installed on your vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Trailer Towing > Page 6557 Trailer Towing Weights (Maximum Trailer Weight Ratings) The following chart provides the maximum trailer weight ratings towable for your given drivetrain. NOTE: The trailer tongue weight must be considered as part of the combined weight of occupants and cargo and should never exceed the weight referenced on the Tire and Loading Information placard. Trailer and Tongue Weight Always load a trailer with 60% to 65% of the weight in the front of the trailer. This places 10% to 15% of the Gross Trailer Weight (GTW) on the tow hitch of your vehicle. Loads balanced over the wheels or heavier in the rear can cause the trailer to sway severely side to side which will cause loss of control of the vehicle and trailer. Failure to load trailers heavier in front is the cause of many trailer accidents. Never exceed the maximum tongue weight stamped on your bumper or trailer hitch. Consider the following items when computing the weight on the rear axle of the vehicle: - The tongue weight of the trailer. - The weight of any other type of cargo or equipment put in or on your vehicle. - The weight of the driver and all passengers. NOTE: Remember that everything put into or on the trailer adds to the load on your vehicle. Also, additional factory-installed options, or dealer-installed options, must be considered as part of the total load on your vehicle. Refer to the Tire and Loading Information placard in the Tire Safety Information Section for the maximum combined weight of occupants and cargo for your vehicle. Towing Requirements To promote proper break-in of your new vehicle drivetrain components, the following guidelines are recommended: CAUTION: - Avoid towing a trailer for the first 500 mi (805 km) of vehicle operation. Doing so may damage the vehicle. - During the first 500 mi (805 km) of trailer towing, limit the speed to 50 mph (80 km/h). When towing a trailer, never exceed the GAWR or GCWR, ratings. WARNING: Improper towing can lead to an injury accident. Follow these guidelines to make the trailer towing as safe as possible: Make certain that the load is secured in the trailer and will not shift during travel. When trailering cargo that is not fully secured, dynamic load shifts can occur that may be difficult for the driver to control. Failure to follow these instructions may result in serious or fatal injury. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Trailer Towing > Page 6558 - When hauling cargo or towing a trailer, do not overload your vehicle or trailer. Overloading can cause a loss of control, poor performance or damage to the brakes, axle, engine, transmission, steering, suspension, chassis structure or tires. - Safety chains must always be used between your vehicle and trailer. Always connect the chains to the frame or hook retainers of the vehicle hitch. Cross the chains under the trailer tongue and allow enough slack for turning corners. - Vehicles with trailers should not be parked on a grade. When parking, apply the parking brake on the tow vehicle. Put the tow vehicle automatic transmission in PARK. With a manual transmission, shift the transmission into REVERSE. Always block or "chock" the trailer wheels. - GCWR must not be exceeded. - Total weight must be distributed between the tow vehicle and the trailer such that the following four ratings are not exceeded: - GVWR - GTW - GAWR - Tongue weight rating for the trailer hitch utilized (this requirement may limit the ability to always achieve the 10% to 15% range of tongue weight as a percentage of total trailer weight). Towing Requirements - Tires - Do not attempt to tow a trailer while using a compact spare tire. - Proper tire inflation pressures are essential to the safe and satisfactory operation of your vehicle. Refer to the "Tires-General Information" section under Tire Pressures for proper tire inflation procedures. - Also, check the trailer tires for proper tire inflation pressures before trailer usage. - Check for signs of tire wear or visible tire damage before towing a trailer. Refer to "Tread Wear Indicators" under "Tires-General Information" in Section 5 under for the proper inspection procedure. - When replacing tires, See: Maintenance/Wheels and Tires/Tires/Description and Operation for information on replacement tires and for the proper tire replacement procedures. Replacing tires with a higher load carrying capacity will not increase the vehicle's GVWR and GAWR limits. Towing Requirements - Trailer Brakes - Do not interconnect the hydraulic brake system or vacuum system of your vehicle with that of the trailer. This could cause inadequate braking and possible personal injury. - An electronically actuated trailer brake controller is required when towing a trailer with electronically actuated brakes. When towing a trailer equipped with a hydraulic surge actuated brake system, an electronic brake controller is not required. - Trailer brakes are recommended for trailers over 1,000 lbs (450 kg) and required for trailers in excess of 2,000 lbs (907 kg). CAUTION: If the trailer weighs more than 1,000 lbs (450 kg) loaded, it should have its own brakes and they should be of adequate capacity. Failure to do this could lead to accelerated brake lining wear, higher brake pedal effort, and longer stopping distances. WARNING: Do not connect trailer brakes to your vehicle's hydraulic brake lines. It can overload your brake system and cause it to fail. You might not have brakes when you need them and could have an accident. Towing any trailer will increase your stopping distance. When towing, you should allow for additional space between your vehicle and the vehicle in front of you. Failure to follow these instructions may result in possible serious or fatal injury. Towing Requirements - Trailer Lights AND Wiring 4 - Pin Connector Whenever you pull a trailer, regardless of the trailer size, stoplights and turn signals on the trailer are required for motoring safety. The Trailer Tow Package may include a 4- and 7-pin wiring harness. Use a factory approved trailer harness and connector. NOTE: Do not cut or splice wiring into the vehicles wiring harness. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Trailer Towing > Page 6559 The electrical connections are all complete to the vehicle but you must mate the harness to a trailer connector. Refer to the following illustrations. 7- Pin Connector Towing Tips Before setting out on a trip, practice turning, stopping and backing the trailer in an area away from heavy traffic. If using a manual transmission vehicle for trailer towing, all starts must be in 1st gear to avoid excessive clutch slippage. Electronic Speed Control (If Equipped) - Do not use in hilly terrain or with heavy loads. - When using the speed control, if you experience speed drops greater than 10 mph (16 km/h), disengage it until you can get back to cruising speed. - Use speed control in flat terrain and with light loads to maximize fuel efficiency. Cooling System To reduce potential for engine and transmission overheating, take the following actions: - City Driving - When stopped for short periods of time, put transmission in neutral and increase engine idle speed. - Highway Driving - Reduce speed. - Air Conditioning - Turn off temporarily. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Trailer Towing > Page 6560 Towing Information: Service and Repair Vehicle Towing VEHICLE TOWING WARNING: Do not allow towing attachment devices to contact the fuel tank or lines, fuel leak can result. Do not lift or tow vehicle by front or rear bumper, or bumper energy absorber units. Do not venture under a lifted vehicle if not supported properly on safety stands. Do not allow passengers to ride in a towed vehicle. Use a safety chain that is independent from the towing attachment device. Failure to follow these instructions may result in possible serious or fatal injury. CAUTION: Do not damage brake lines, exhaust system, shock absorbers, sway bars, or any other under vehicle components when attaching towing device to vehicle. Do not attach towing device to front or rear suspension components. Do not secure vehicle to towing device by the use of front or rear suspension or steering components. Remove or secure loose or protruding objects from a damaged vehicle before towing. Refer to state and local rules and regulations before towing a vehicle. Do not allow weight of towed vehicle to bear on lower fascia, air dams, or spoilers. To avoid damage to bumper fascia and air dams use of a wheel lift or flat bed towing device is recommended. When using a wheel lift towing device, be sure the un-lifted end of disabled vehicle has at least 100 mm (4 in.) ground clearance. If minimum ground clearance cannot be reached, use a towing dolly. If a flat bed device is used, the approach angle should not exceed 15 degrees. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Trailer Towing > Page 6561 Towing Information: Service and Repair Recreational Towing (Behind Motorhome, etc.) STANDARD PROCEDURE - RECREATIONAL TOWING (BEHIND MOTORHOME, ETC.) Towing This Vehicle Behind Another Vehicle (Flat Towing With All Four Wheels On The Ground) NOTE: Vehicles equipped with manual transaxles may be recreationally towed (flat towed) at any legal highway speed, for any distance, if the manual transaxle is in NEUTRAL and the ignition key is in the ACC position. CAUTION: - DO NOT FLAT TOW any vehicle equipped with an AUTOMATIC TRANSAXLE. Damage to the drivetrain will result. If these vehicles require towing, make sure all four wheels are off the ground. - Front or rear wheel lifts should not be used. Internal damage to the transaxle will occur if a front or rear wheel lift is used when recreational towing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6567 It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6568 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6569 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6570 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6571 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6572 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6573 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6574 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6575 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6576 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6577 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6578 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6579 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6580 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6581 Trailer Connector: Connector Views Connector (TRAILER TOW) - (TRAILER TOW) 4 WAY WIRING-TRAILER TOW 4-WAY (TRAILER TOW) - (TRAILER TOW) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Diagrams > Trailer Tow Lamp Relay (Trailer Tow) 4 Way Trailer Towing Relay: Diagrams Trailer Tow Lamp Relay (Trailer Tow) 4 Way Connector - (TRAILER TOW) 4 WAY RELAY-TRAILER TOW BRAKE LAMP - (TRAILER TOW) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Diagrams > Trailer Tow Lamp Relay (Trailer Tow) 4 Way > Page 6587 Trailer Towing Relay: Diagrams Left Trailer Tow Relay (Trailer Tow) 5 Way Connector - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW-LEFT - (TRAILER TOW) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Diagrams > Trailer Tow Lamp Relay (Trailer Tow) 4 Way > Page 6588 Trailer Towing Relay: Diagrams Right Trailer Tow Relay (Trailer Tow) 5 Way Connector - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW-RIGHT - (TRAILER TOW) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6594 It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6595 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6596 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6597 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6598 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6599 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6600 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6601 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6602 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6603 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6604 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6605 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6606 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6607 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6608 Trailer Connector: Connector Views Connector (TRAILER TOW) - (TRAILER TOW) 4 WAY WIRING-TRAILER TOW 4-WAY (TRAILER TOW) - (TRAILER TOW) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations Voice Activation Module: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 6613 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 6614 Voice Activation Module: Diagrams Connector - (INSTRUMENT PANEL) 22 WAY MODULE-HANDS FREE - (INSTRUMENT PANEL) 22 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia - Removal Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia - Removal REMOVAL 1. Remove splash shield. See: Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 2. Remove left and right side fastener (1) located in the wheel well. 3. Remove three fasteners (2) located at the bottom of fascia. 4. Remove middle fasteners (8) located on the top of the fascia. 5. If equipped, disconnect fog lamps (1). 6. Remove two fasteners located at the top of fascia (7). 7. Carefully, remove fascia from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia - Removal > Page 6622 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia - Installation INSTALLATION 1. Lift fascia (2) and fasten both sides of fascia notch (3) onto push pin (6). 2. Install fasteners (1) located inside wheel well up through fascia. 3. Install fascia fasteners (7). 4. Install fascia fasteners (8) through fascia. 5. If equipped, connect wire harness (5) to fog lamp (4). 6. Raise vehicle. 7. Install push pins into locations (1). 8. Install fasteners (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Reinforcement - Removal Front Bumper Reinforcement: Service and Repair Front Bumper Reinforcement - Removal REMOVAL 1. Remove fascia. See: Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Removal 2. Disconnect wire connector (2) and remove horn (3).See: Lighting and Horns/Horn/Service and Repair/Horn - Removal 3. Remove wire harness push pin fastener (1). 4. Remove wire harness (1) from bottom of bumper reinforcement. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Reinforcement - Removal > Page 6627 5. Remove 8 fasteners (2) from bumper reinforcement (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Reinforcement - Removal > Page 6628 Front Bumper Reinforcement: Service and Repair Front Bumper Reinforcement - Installation INSTALLATION 1. Install fasteners (2) and torque to 23 Nm (204 in. lbs.). 2. Connect wire connector (2) and install horn (1). See: Lighting and Horns/Horn/Service and Repair/Horn - Installation 3. Install wiring harness push pin. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Reinforcement - Removal > Page 6629 4. Install wire connector (1) to bumper reinforcement. 5. Install front fascia.See: Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia - Removal Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia - Removal REMOVAL 1. Remove push pins (5) from holes (1) located on vehicle (2). 2. Remove rear splash shields. 3. Remove both left (7) and right screws (4). 4. Remove fascia from push pins (10). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia - Removal > Page 6635 Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia - Installation INSTALLATION 1. Raise fascia (6) and hang fascia onto push pins (10). 2. Install push pins (5) into push pin locations (1). 3. Install left (7) and right (4) screws into their respective locations. 4. Install splash shields. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Rear Bumper Reinforcement - Removal Rear Bumper Reinforcement: Service and Repair Rear Bumper Reinforcement - Removal REMOVAL 1. Remove rear fascia.. See: Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Removal 2. Remove seven bumper reinforcement nuts (1). 3. Remove bumper reinforcement (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Rear Bumper Reinforcement - Removal > Page 6640 Rear Bumper Reinforcement: Service and Repair Rear Bumper Reinforcement - Installation INSTALLATION 1. Place bumper reinforcement (2) up to frame locations. 2. Install seven nuts (1) and tighten to 23 Nm (204 in. lbs.) 3. Install fascia. . See: Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Cover - Removal Cowl Moulding / Trim: Service and Repair Cowl Panel Cover - Removal REMOVAL 1. Remove the wiper arms (2), . See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 2. Remove the hood seal (4). 3. Remove the screws (3) and remove the panel (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Cover - Removal > Page 6646 Cowl Moulding / Trim: Service and Repair Cowl Panel Cover - Installation INSTALLATION 1. Position the end seals (1) into place. 2. Install the panel (2) and install the screws (3). 3. Install the hood seal (4). 4. Install the wiper arms (2), . See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Front Exterior Handle - Removal Front Door Exterior Handle: Service and Repair Front Exterior Handle - Removal REMOVAL 1. Remove bolster. See: Front Door Panel/Service and Repair/Front Door Trim Panel Bolster Removal 2. Remove door plugs.See: Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Removal 3. Remove door module. See: Service and Repair/Front Door Carrier Plate Removal 4. Release the rear window guide rail and lower the rail to gain access to the exterior handle fasteners. 5. Remove the key cylinder lock link rod (5) from lock cylinder (1). 6. Remove the handle link rod (4) from handle (2). 7. Remove screws (6) from the handle assembly (2). 8. Remove the handle assembly (2) from the door (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Front Exterior Handle - Removal > Page 6655 Front Door Exterior Handle: Service and Repair Front Exterior Handle - Installation INSTALLATION 1. Install the handle assembly (2) to the door (3). 2. Install the screws (6) to the handle assembly (2). 3. Tighten screws (6) to 8 Nm (6 ft. lbs.) 4. Connect the handle link rod (4) on to the door handle (2). 5. Connect the lock cylinder link rod (5) on to the lock cylinder (1). 6. Insert the lock cylinder (1) into the door handle (2) then into door opening. 7. Raise the engage rear window guide rail to the door assembly (3) 8. Install the door module.See: Service and Repair/Front Door Carrier Plate Installation 9. Install the door plugs.See: Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Installation 10. Install the bolster.See: Front Door Panel/Service and Repair/Front Door Trim Panel Bolster Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Front Interior Door Handle - Removal Front Door Interior Handle: Service and Repair Front Interior Door Handle - Removal REMOVAL 1. Unsnap link rod to latch (1). 2. Remove screw (3) attaching plate to panel. 3. Unsnap housing snaps from (2) belt line ribs on trim panel. 4. Pull up on trim panel belt line to aid in unsnapping of housing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Front Interior Door Handle - Removal > Page 6660 Front Door Interior Handle: Service and Repair Front Interior Door Handle - Installation INSTALLATION 1. Snap inside handle to belt line ribs (2) on trim panel. 2. Install screw (3) attaching handle to panel. 3. Snap link rod to latch. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Front Door Hinge: Customer Interest Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 6669 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 6670 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Front Door Hinge: All Technical Service Bulletins Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 6676 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 6677 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 6678 Front Door Hinge: By Symptom Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 6679 SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 6680 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 6681 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 6682 CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Front Door Hinge - Removal Front Door Hinge: Service and Repair Front Door Hinge - Removal REMOVAL 1. Remove nuts (3) from door studs (1). 2. Remove door. 3. Disconnect door harness (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Front Door Hinge - Removal > Page 6685 Front Door Hinge: Service and Repair Front Door Hinge - Installation INSTALLATION 1. Connect door harness (2). 2. Install door studs (1) into door hinges. 3. Install nuts (3) onto door studs. Tighten to 26 Nm (19 ft. lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments Front Door Latch: Adjustments COUPE 1. Insert a Torx(R)-wrench through the elongated hole in the door end frame near the latch striker opening. 2. Loosen Torx(R) head screw on the side of the latch linkage. 3. Push button on outside door handle and release it. 4. Tighten Torx(R) head screw on latch. 5. Verify latch operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front Door Latch - Removal Front Door Latch: Service and Repair Front Door Latch - Removal REMOVAL 1. If equipped, disconnect wire harness from Latch. 2. Disconnect inside hand link (5) and lock rod (6) from latch (4). 3. Unscrew latch presenter or unsnap latch from presenter. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front Door Latch - Removal > Page 6691 Front Door Latch: Service and Repair Front Door Latch - Installation INSTALLATION 1. Move glass to the full up position. 2. Install latch assembly into door face (1). 3. Connect hand link (5) and lock rod (6) into latch. 4. Install fasteners and torque to 9 Nm (7 ft. lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel Bolster - Removal Front Door Panel: Service and Repair Front Door Trim Panel Bolster - Removal REMOVAL 1. Remove pull-cup screw (1). 2. Remove window crank (1) from spindle if equipped. 3. Using trim stick C-4755, start at the lower corner and pull in the direction of the arrows. Bolster should unsnap. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel Bolster - Removal > Page 6696 4. Remove sock seal (1) and (3) that wraps around switch bezel and wire harness. Disconnect wire connectors (2). 5. Remove switch bezel from bolster. 6. Remove bolster by unsnapping plastic tethers (1) from bolster back side of surface. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel Bolster - Removal > Page 6697 Front Door Panel: Service and Repair Front Door Trim Panel Bolster - Installation INSTALLATION 1. Connect bolster to door module tethers (1). 2. Connect wire connectors (2) and close sock seal (1). 3. Replace window crank (1) to spindle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel Bolster - Removal > Page 6698 4. Replace pull cup screw. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Latch Striker - Removal Front Door Striker: Service and Repair Door Latch Striker - Removal REMOVAL 1. Remove fasteners (2) from door jamb. 2. Remove door striker (1) from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Latch Striker - Removal > Page 6703 Front Door Striker: Service and Repair Door Latch Striker - Installation INSTALLATION 1. Install striker (1) onto door jamb. 2. Install fasteners (2) into striker. 3. Tighten fasteners to 26 Nm (19 ft. lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Front Door Glass - Removal Front Door Window Glass: Service and Repair Front Door Glass - Removal REMOVAL 1. Remove bolster.See: Front Door Panel/Service and Repair/Front Door Trim Panel Bolster Removal 2. Move glass to line up snap plates with access holes (1). 3. Using a punch or equivalent, press tabs releasing glass from window regulator. 4. Manually move glass upward to full up position and remove from window frame. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Service and Repair > Front Door Glass - Removal > Page 6708 Front Door Window Glass: Service and Repair Front Door Glass - Installation INSTALLATION 1. Insert glass into glass channel and slide down ensuring access holes (1) align with snaps. 2. Ensure access holes properly lock into snaps (1). 3. Install bolster. See: Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Window Regulator Motor - Removal Front Door Window Motor: Service and Repair Window Regulator Motor - Removal REMOVAL 1. Move the window to the full UP position, if possible. 2. Disconnect and isolate the battery negative cable. 3. Remove the front door module. See: Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Removal. 4. Disconnect electrical harness connector from motor. 5. Remove window regulator. 6. With regulator on bench, remove four screws retaining the motor to the regulator and remove motor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Window Regulator Motor - Removal > Page 6713 Front Door Window Motor: Service and Repair Window Regulator Motor - Installation INSTALLATION 1. With regulator on bench, install four screws retaining the motor to the regulator. 2. Install the window regulator. 3. Connect the electrical harness connector to window motor. 4. Install the door module See: Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Installation. 5. Connect battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal Front Door Window Regulator: Service and Repair Front Door Window Regulator - Removal REMOVAL 1. Remove the carrier plate (1). See: Service and Repair/Front Door Carrier Plate - Removal 2. Remove the motor or manual lift mechanism screws (2). 3. Remove the lower regulator screws (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal > Page 6718 4. Disconnect the regulator motor (1) electrical connector (7), if equipped. 5. Separate the regulator runners (5) from the support brackets (6) and remove the regulator assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal > Page 6719 Front Door Window Regulator: Service and Repair Front Door Window Regulator - Installation INSTALLATION 1. Position the regulator assembly onto the door trim panel and seat the runner support clips (6) fully. 2. Connect the regulator motor (1) electrical connector (7). 3. Install the lower regulator screws (2) but do not tighten them at this time. 4. Install the motor or manual lift mechanism screws (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal > Page 6720 5. Install the carrier plate (1). See: Service and Repair/Front Door Carrier Plate - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Exterior Door Handle - Removal Rear Door Exterior Handle: Service and Repair Rear Exterior Door Handle - Removal REMOVAL 1. Remove door plugs. See: Rear Door Panel/Service and Repair/Rear Door Trim Panel Bolster Removal 2. Remove bolster. See: Rear Door Panel/Service and Repair/Rear Door Trim Panel Bolster - Removal 3. Remove door module. See: Service and Repair/Rear Door - Removal 4. Remove rod link (1). 5. Remove fasteners (3). 6. Remove handle (2) from door. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Exterior Door Handle - Removal > Page 6727 Rear Door Exterior Handle: Service and Repair Rear Exterior Door Handle - Installation INSTALLATION 1. Install door handle (2). 2. Install three fasteners. Tighten to 8 Nm (6 ft. lbs.). 3. Install rod link (1). 4. Install door module.See: Service and Repair/Rear Door - Installation 5. Install bolster.See: Rear Door Panel/Service and Repair/Rear Door Trim Panel Bolster - Installation 6. Install door plugs. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Rear Door Hinge: Customer Interest Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 6736 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 6737 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Rear Door Hinge: All Technical Service Bulletins Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 6743 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 6744 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 6745 Rear Door Hinge: By Symptom Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 6746 SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 6747 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 6748 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 6749 CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Door Hinge - Removal Rear Door Hinge: Service and Repair Rear Door Hinge - Removal REMOVAL 1. Disconnect wire harness (4). 2. Remove nuts (1) fastening door hinge (2) to door studs. 3. With the help of an assistant, remove door (7) from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Door Hinge - Removal > Page 6752 Rear Door Hinge: Service and Repair Rear Door Hinge - Installation INSTALLATION 1. With the help of an assistant, have the assistant align door studs through hinge (2). 2. Install nuts and torque nuts to 26 Nm (19 ft. lbs.) 3. Connect wire connector (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Adjustments Rear Door Latch: Adjustments ADJUSTMENTS 1. Insert a Torx(R) wrench through the elongated hole in the door end frame near the latch striker opening. 2. Loosen screw on the side of the latch linkage. 3. Push button on outside door handle and release it. 4. Tighten screw on latch. 5. Verify latch operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch - Removal Rear Door Latch: Service and Repair Rear Door Latch - Removal REMOVAL 1. Remove window crank handle (4) and washer if equipped. 2. Remove rear door trim bolster. See: Rear Door Panel/Service and Repair/Rear Door Trim Panel Bolster - Removal 3. Remove door plugs. 4. Remove rear door module. 5. If equipped, remove wire connector. 6. Remove latch rod (4) from latch (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch - Removal > Page 6758 7. Remove fasteners (4) from latch (2). 8. Remove latch from door. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch - Removal > Page 6759 Rear Door Latch: Service and Repair Rear Door Latch - Installation INSTALLATION 1. Install latch into door (1) and align latch (2) with fastener openings. 2. Install fasteners (4) into latch (2). Tighten to 9 Nm (7ft.lbs.) 3. Connect rod (4) to latch (3). 4. If equipped, connect wire connector to latch. 5. Install door module. 6. Install bolster. See: Rear Door Panel/Service and Repair/Rear Door Trim Panel Bolster - Installation 7. Install door plugs. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch - Removal > Page 6760 8. If equipped, install window crank (4) and washer. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel Bolster - Removal Rear Door Panel: Service and Repair Rear Door Trim Panel Bolster - Removal REMOVAL 1. Remove screw (1) from pull cup. 2. If equipped, remove window crank (4) and washer (5) from bolster (3). 3. Using trim stick C-4755, unsnap bolster from door panel. 4. If equipped, disconnect wire connector from window switch. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel Bolster - Removal > Page 6765 Rear Door Panel: Service and Repair Rear Door Trim Panel Bolster - Installation INSTALLATION 1. Connect wire harness (7) to window switch connector (4). 2. Align bolster (3) with door and hand tap bolster to door ensuring fit. 3. Insert screw (1) into pull cup and tighten. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair > Door Latch Striker - Removal Rear Door Striker: Service and Repair Door Latch Striker - Removal REMOVAL 1. Open door. 2. Remove fasteners (2). 3. Remove striker (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair > Door Latch Striker - Removal > Page 6770 Rear Door Striker: Service and Repair Door Latch Striker - Installation INSTALLATION 1. Align striker (1) with holes in body. 2. Install fasteners. 3. Tighten fasteners to 26 Nm (19 ft. lbs.) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Rear Door Glass - Removal Rear Door Window Glass: Service and Repair Rear Door Glass - Removal REMOVAL 1. Remove speaker and grille.See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Speaker Removal 2. Remove bolster.See: Rear Door Panel/Service and Repair/Rear Door Trim Panel Bolster Removal 3. Remove door module.See: Service and Repair/Rear Door - Removal 4. Raise window (5) gaining access to window tabs. 5. With a punch or equivalent, press regulator tabs holding window in regulator (3). 6. Carefully, remove window (5). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Rear Door Glass - Removal > Page 6775 Rear Door Window Glass: Service and Repair Rear Door Glass - Installation INSTALLATION 1. Install window regulator to door panel. See: Rear Door Window Regulator/Service and Repair/Rear Door Window Regulator - Installation 2. Install glass (1) down through window channel into window regulator (2) ensuring glass properly seats in access holes. 3. Connect wire connectors. 4. Install door module.See: Service and Repair/Rear Door - Installation 5. Install bolster.See: Rear Door Panel/Service and Repair/Rear Door Trim Panel Bolster - Installation 6. Install speaker and grille.See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Speaker Removal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Removal Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Removal REMOVAL 1. Remove door module.See: Service and Repair/Rear Door Carrier Plate - Removal. 2. Remove door glass (5).See: Rear Door Window Glass/Service and Repair/Rear Door Glass - Installation 3. Remove fasteners, wire connectors and remove window regulator (1) from door panel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Removal > Page 6780 Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Installation INSTALLATION 1. Fasten window regulator to door panel. 2. Connect wire connectors. 3. Install glass ensuring proper seat. See: Rear Door Window Glass/Service and Repair/Rear Door Glass - Installation 4. Install door module. See: Service and Repair/Rear Door Carrier Plate - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Fill Door - Removal Fuel Door: Service and Repair Fuel Fill Door - Removal REMOVAL 1. Remove fuel filler door fasteners (4). 2. Remove fuel filler door. 3. Remove fuel filler housing screws. 4. Remove fuel filler housing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Fill Door - Removal > Page 6785 Fuel Door: Service and Repair Fuel Fill Door - Installation INSTALLATION 1. Install fuel filler housing (2). 2. Install fuel housing screws. 3. Align fuel door (1) with fuel door holes. 4. Fasten fuel door (1) to fender (3) with fasteners. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Hood Hinge - Removal Hood Hinge: Service and Repair Hood Hinge - Removal REMOVAL 1. With the help of an assistant, have the assistant hold the opposite side of hood that is being worked on. 2. Remove fasteners (2) from hinge (1). 3. Remove hood from hinge (1).See: Service and Repair/Hood - Removal 4. Repeat step if necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Hood Hinge - Removal > Page 6791 Hood Hinge: Service and Repair Hood Hinge - Installation INSTALLATION 1. Align hood hinge with fastener holes. 2. Install fasteners (2) in to hinge holes. 3. Tighten nuts (3) to 20 Nm (15 ft.lbs.). 4. Install hood to hinge. See: Service and Repair/Hood - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair > Hood Insulation - Removal Hood Insulator / Pad: Service and Repair Hood Insulation - Removal REMOVAL 1. Remove two push pins (1) fastening hood insulation (2) to hood (3). 2. Remove insulation from hood by pulling insulation outward from hood tabs. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair > Hood Insulation - Removal > Page 6796 Hood Insulator / Pad: Service and Repair Hood Insulation - Installation INSTALLATION 1. Insert hood insulation (2) into hood tabs. 2. Insert push two pins (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch - Removal Hood Latch: Service and Repair Hood Latch - Removal REMOVAL 1. Press down latch release (3) and remove cable (2) from grommet. 2. Remove cable from latch (3). 3. Remove fasteners. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch - Removal > Page 6801 Hood Latch: Service and Repair Hood Latch - Installation INSTALLATION 1. Install cable (2) into latch (3) and route end of cable (1). Pull cable into latch (3) ensuring proper seat. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Release Cable - Removal Hood Latch Release Cable: Service and Repair Hood Release Cable - Removal REMOVAL 1. Remove the wheel mounting nuts, then the front drivers side tire. 2. Remove front drivers side splash shield.See: Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield Removal NOTE: See cable route. 3. Press down latch release (3) and remove cable (2) from grommet (1). 4. Remove cable (2) from latch (3). 5. Follow cable and remove cable from push pin grommets. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Release Cable - Removal > Page 6806 6. Remove fasteners (2) from hood release located inside vehicle. 7. Remove cable from hood release (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Release Cable - Removal > Page 6807 Hood Latch Release Cable: Service and Repair Hood Release Cable - Installation INSTALLATION 1. Install fasteners (2). 2. Install cable into hood release lever (3), and route cable (4) through grommet. 3. Remove splash shield.See: Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 4. Route cable along underneath splash shield and route toward radiator support. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Release Cable - Removal > Page 6808 5. Insert cable (2) into latch (3) and route front of cable (1) into access hole. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams > Liftgate Door Latch C1 (Liftgate) 3 Way Power Trunk / Liftgate Lock Actuator: Diagrams Liftgate Door Latch C1 (Liftgate) 3 Way Connector C1 - (LIFTGATE) 3 WAY LATCH-DOOR-LIFTGATE - (LIFTGATE) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams > Liftgate Door Latch C1 (Liftgate) 3 Way > Page 6819 Power Trunk / Liftgate Lock Actuator: Diagrams Liftgate Door Latch C2 (Liftgate) 2 Way Connector C2 - (LIFTGATE) 2 WAY LATCH-DOOR-LIFTGATE - (LIFTGATE) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Hinge - Removal Trunk / Liftgate Hinge: Service and Repair Hinge - Removal REMOVAL 1. Release liftgate latch and open liftgate. 2. Disconnect liftgate harness and washer hose. 3. Support liftgate with a suitable lifting device in the full open position on the side of the vehicle being serviced. 4. Remove the two screws that secure the liftgate hinge (1) to the liftgate. 5. Remove liftgate (1) from hinge (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Hinge - Removal > Page 6824 6. Carefully, move down headliner and remove two nuts and one fastener. Remove hinge from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Hinge - Removal > Page 6825 Trunk / Liftgate Hinge: Service and Repair Hinge - Installation INSTALLATION 1. With the help of an assistant, align liftgate (1) with liftgate hinge (3). 2. Carefully, pry down headliner and install fastener, washers and nuts. 3. Tighten nuts 20 Nm (15 ft. lbs). 4. Install gas props. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Hinge - Removal > Page 6826 5. Connect liftgate harness (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Exterior Handle Lamp Bar - Removal Trunk / Liftgate Handle: Service and Repair Exterior Handle Lamp Bar - Removal REMOVAL 1. Remove liftgate upper molding. 2. Remove liftgate upper side molding. 3. Remove liftgate lower molding.See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal 4. Remove nuts from light bar studs. 5. Disconnect wire connector. 6. Disconnect cable from handle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Exterior Handle Lamp Bar - Removal > Page 6831 Trunk / Liftgate Handle: Service and Repair Exterior Handle Lamp Bar- Installation INSTALLATION 1. Connect wire connector (2). 2. Connect cable to light bar handle. 3. Align light bar studs through liftgate holes. 4. Install nuts to light bar studs. 5. Install liftgate lower trim panel.See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Installation 6. Install liftgate side moldings. 7. Install liftgate upper molding. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel - Removal Trunk / Liftgate Interior Trim Panel: Service and Repair Liftgate Trim Panel - Removal Upper REMOVAL 1. Using trim stick C-4755 or equivalent, pry up on upper trim(1) ensuring trim tabs disengage. 2. Remove from vehicle. Lower With Speaker REMOVAL 1. Remove trim panel fasteners (2). 2. Using trim-stick C-4755, pry up on trim panel and remove trim panel from liftgate. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel - Removal > Page 6836 3. Remove six speaker fasteners. 4. Disconnect speaker wire from harness. Lower Without Speaker REMOVAL 1. Remove upper liftgate molding. 2. Remove liftgate upper side molding. 3. Remove liftgate screws (2) from liftgate nuts (1). 4. Using special tool C-4755, pry up liftgate trim tabs (4) from liftgate. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel - Removal > Page 6837 5. Remove lower liftgate trim (3) from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel - Removal > Page 6838 Trunk / Liftgate Interior Trim Panel: Service and Repair Liftgate Trim Panel - Installation Upper INSTALLATION 1. Align molding tabs (2) with holes in liftgate. 2. Hand tap trim (1) onto liftgate holes at clip locations. Lower With Speaker INSTALLATION 1. Connect speaker connector to wire harness. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel - Removal > Page 6839 2. Fasten speaker to liftgate. 3. Align trim panel to liftgate holes and install trim panel fasteners. Lower Without Speaker INSTALLATION 1. Align lower liftgate trim tabs (4) with liftgate holes. 2. Hand tap liftgate panel ensuring liftgate tabs are properly seated. 3. Install liftgate screws (2) into liftgate nuts (1). 4. Install upper side molding. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel - Removal > Page 6840 5. Install upper liftgate molding. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch - Removal Trunk / Liftgate Latch: Service and Repair Latch - Removal REMOVAL 1. Remove three fasteners (1). 2. Disconnect wire connectors. 3. Disconnect cable from outer handle hole. 4. Disconnect cable from latch. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Latch - Removal > Page 6845 Trunk / Liftgate Latch: Service and Repair Latch - Installation INSTALLATION 1. Connect wire connectors. 2. Install latch assembly into liftgate pocket. 3. Install three fasteners (1). 4. Tighten fasteners to 8 Nm (6 ft. lbs.). 5. Install cable fastener to liftgate inner while working the cable upward. 6. Guide cable upward through opening and tuck into the outer handle hole. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Gas Prop - Removal Trunk / Liftgate Shock / Support: Service and Repair Gas Prop - Removal REMOVAL 1. Open the liftgate and support. 2. Using a small flat bladed tool, or equivalent, release the retaining clips while pulling the ball socket away from the ball stud. NOTE: Lift the clips only enough to release the ball studs. 3. Remove the support cylinder. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Gas Prop - Removal > Page 6850 Trunk / Liftgate Shock / Support: Service and Repair Gas Prop - Installation INSTALLATION 1. Make sure the retaining clips are seated into the ball socket (2) fully. 2. Install the support cylinder over the ball studs with the thin end connected to the liftgate and the retaining clips snapping into place. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair > Striker - Removal Trunk / Liftgate Striker: Service and Repair Striker - Removal REMOVAL 1. Open the liftgate. 2. Remove the liftgate sill scuff plate See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Scuff Plate - Removal. NOTE: Place a reference mark along the outer edge of the striker to ensure it is reinstalled to its original position. 3. Mark the position of the striker (1) on the liftgate opening lower panel to aid installation. 4. Remove the two screws (4) that secure the striker to the lower panel and remove the striker. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair > Striker - Removal > Page 6855 Trunk / Liftgate Striker: Service and Repair Striker - Installation INSTALLATION 1. Position the liftgate striker (1) onto the liftgate opening lower panel and align the striker to the previously marked location. 2. Install the two bolts (4) that secure the striker to the lower panel. Tighten the bolts to 23 Nm (17 ft. lbs.). 3. Verify liftgate alignment and latch operation. The liftgate should fit flush and have even gaps to adjacent body panels. Gap specifications are as follows: 7 mm (0.280 in.) to the fascia. - 6 mm (0.240 in.) to the roof header. - 4 mm (0.160 in.) to the body side. 4. Install the liftgate sill scuff plate See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Scuff Plate - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Cover - Removal Cowl Moulding / Trim: Service and Repair Cowl Panel Cover - Removal REMOVAL 1. Remove the wiper arms (2), . See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 2. Remove the hood seal (4). 3. Remove the screws (3) and remove the panel (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Cover - Removal > Page 6861 Cowl Moulding / Trim: Service and Repair Cowl Panel Cover - Installation INSTALLATION 1. Position the end seals (1) into place. 2. Install the panel (2) and install the screws (3). 3. Install the hood seal (4). 4. Install the wiper arms (2), . See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Body Cladding - Removal Lower Side Moulding / Trim: Service and Repair Body Cladding - Removal REMOVAL 1. Remove the end screws (3) from the cladding (2). Two screws in the front and one screw in the rear wheel well. 2. Remove the push pin fasteners (4) along the bottom of the cladding (5). 3. Using a trim stick or equivalent, gently pry out on the front of the cladding (5) which is attached with two sided tape. 4. Using a trim stick or equivalent, gently pry out on the cladding to disconnect it from the side rocker panel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Body Cladding - Removal > Page 6866 Lower Side Moulding / Trim: Service and Repair Body Cladding - Installation INSTALLATION NOTE: If reusing an old cladding, the two sided tape MUST be replaced to insure a tight seal to the fender and not rattles. 1. Position the cladding onto the vehicle and align the cladding over the holes in the rocker panel. Push firmly in on the outer side of the cladding to make sure it is snapped in. 2. Install the push pins (4) along the bottom of the cladding making sure each one is a tight fit. NOTE: If any of the push pins were damaged upon removal, then they must be replaced to insure no BSR's. 3. Install the end screws (3), two in the front and one in the rear wheel well. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Underbody Cover > Component Information > Service and Repair > Belly Pan - Removal Underbody Cover: Service and Repair Belly Pan - Removal REMOVAL 1. Remove fasteners from belly pan. 2. Carefully, remove belly pan from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Underbody Cover > Component Information > Service and Repair > Belly Pan - Removal > Page 6871 Underbody Cover: Service and Repair Belly Pan - Installation INSTALLATION 1. Position belly pan on to vehicle 2. Install fasteners. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Splash Shield - Removal Front Fender Liner: Service and Repair Splash Shield - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the front wheels. See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Removal. 3. Remove push pins (2) and (3). 4. Remove screws (4) and (5) 5. Remove splash shield (6) from wheelhouse. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Splash Shield - Removal > Page 6878 Front Fender Liner: Service and Repair Splash Shield - Installation INSTALLATION 1. Raise and support vehicle. 2. Remove front wheels. See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Removal 3. Raise splash shield (5) up to wheel house and align with holes in quarter panel (6). 4. Install push pins (2)and (3). 5. Install screws (6) and (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair > Splash Shield - Removal Rear Fender Liner: Service and Repair Splash Shield - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the left and right rear wheel.See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels Removal 3. Remove push pins (2) and (3). 4. Remove fasteners (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair > Splash Shield - Removal > Page 6884 Rear Fender Liner: Service and Repair Splash Shield - Installation INSTALLATION NOTE: Left hand side has 2 additional push pins as it has additional material to cover the fuel filler tube. 1. Place splash shield (1) up to wheel house (5) and align splash shield holes with fender. 2. Install fasteners (4). 3. Install push pins (2) and (3). 4. Install the rear wheels. See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal Cross-Member: Service and Repair Crossmember - Removal Front Fore and Aft REMOVAL 1. Raise and support the vehicle, See: Maintenance/Vehicle Lifting/Service and Repair. 2. Remove the four wheel well screws. 3. If equipped, remove the three front screws (4), the three rear screws (2) and one push pin fastener from the center of the belly pan. 4. Remove the crossmember bolts (1, 2 and 3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6890 5. Remove the engine roll mount (3) through bolt (2) and remove the fore/aft crossmember (4). Front Suspension REMOVAL 1. Raise and support the vehicle, See: Maintenance/Vehicle Lifting/Service and Repair. 2. Remove the four wheel well screws. 3. If equipped, remove the three front screws (4), the three rear screws (2) and one push pin fastener from the center of the belly pan. 4. Remove the rear roll mount (4) through bolt (2). 5. Remove the three bolts (3) attaching the rear roll mount (5) to the crossmember and remove the mount. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6891 6. Remove the for/aft crossmember (4) See: . 7. Remove the front wheels (1), See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Removal. 8. Remove the lower ball joint (6) pinch bolts (4) and nuts (5). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6892 9. Remove the bolt attaching the pressure line routing bracket to the steering gear. 10. Remove the bolt attaching the return line to the crossmember. 11. Remove the sway bar bushing bolts (1) and support the sway bar (2) up in the vehicle. 12. Remove the steering gear mounting bolts (1) and support the steering gear (2) up in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6893 13. Mark the crossmember (3) to body location (1) using a grease pencil (2) or equivalent. 14. Support the crossmember with a suitable lifting device. 15. Remove the crossmember bolts (1 and 2) and lower the crossmember from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6894 16. Remove the lower control arm (3) front pivot bolts (2). 17. Remove the lower control arm rear pivot bolts (3) and separate the lower control arms from the crossmember (1). Rear Suspension REMOVAL 1. Remove the park brake shoes See: Brakes and Traction Control/Parking Brake System/Parking Brake Shoe/Service and Repair/Removal. 2. Remove the park brake cable from lever. 3. Remove the hair pin clip and separate the brake cable (2) from the backing plate (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6895 4. Remove the bolt (2) and separate the brake line (1) from the trailing arm (3). 5. Remove the bolt (1), the clip (2) and separate the brake line (3) from the trailing arm. 6. Separate the wheel speed sensors and position aside as necessary to remove the crossmember, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Wheel Speed Sensor Removal/Rear 7. Remove the lower strut bolts. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6896 8. Remove the trailing link bushing bolts. 9. Support the rear cradle with a suitable lifting device. 10. Remove the rear cradle bolts and lower the cradle assembly from vehicle. 11. Remove the lower stabilizer link nuts (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6897 12. Remove the lower link bolts (5 and 6) at the cradle. 13. Remove the upper link bolts (2) at the cradle. 14. Remove the toe link cam bolts (1) at the cradle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6898 15. Remove the suspension knuckle assemblies. 16. Remove the stabilizer bushing bolts (1) and separate the stabilizer bar from the cradle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6899 Cross-Member: Service and Repair Crossmember - Installation Front Fore and Aft INSTALLATION 1. Install the fore/aft crossmember and install the engine anti-roll mount (3) through bolt (2). 2. Install the bolts (1, 2 and 3), and tighten using the following sequence: a. Tighten the bolt (1) to 78 Nm (58 ft. lbs.). b. Tighten the bolt (2) to 78 Nm (58 ft. lbs.). c. Tighten the bolt (3) to 129 Nm (95 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6900 3. Tighten the bolt (2) to 65 Nm (48 ft. lbs.). 4. If equipped, install the belly pan. 5. Install the three front screws (4), the three rear screws (2) and on push pin fastener into the center of the belly pan. Front Suspension INSTALLATION 1. Install the lower control arms and install the rear pivot bolts (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6901 2. Install the front pivot bolts (2). If built before 8/1/08, tighten to 135 N-m (100 ft. lbs.). If built after 8/1/08, tighten to 160 N-m (118 ft. lbs.). 3. Support the crossmember on a suitable lifting device. 4. Raise the crossmember into position onto the vehicle. 5. Install the bolts (1 and 2) and align the engine cradle to the marks made during removal. 6. Tighten the bolts to 150 Nm (111 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6902 7. Position the steering gear back into place and install the bolts (1). 8. Tighten the bolts to 70 Nm (52 ft. lbs.). 9. Position the stabilizer bar (2) back into place and install the bushing bolts (1). 10. Tighten the bolts to 61 Nm (45 ft. lbs.). 11. Position the power steering lines back into place and install the support bracket (2) bolts (1). 12. Tighten the bolts to 8 Nm (70 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6903 13. Connect the lower ball joint stud (6) to the knuckle (3). 14. Install a NEW ball joint stud pinch bolt (4) and nut (5). Tighten the nut to 82 Nm (60 ft. lbs.). 15. Install the fore/aft crossmember (4), See: 16. Install the front wheels (1), See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement/Tires and Wheels - Installation 17. With the full weight of the vehicle on the suspension tighten the front control arm bushing bolts to 123 Nm (91 ft. lbs.) 18. Perform wheel alignment as necessary. See: Maintenance/Alignment/Service and Repair Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6904 19. Install the rear roll mount (4) and install the three bolts (3) attaching it to the crossmember. 20. Tighten the bolts (3) to 153 Nm (112 ft. lbs.). 21. Install the through bolt (2) and tighten to 65 Nm (48 ft. lbs.). 22. If equipped, install the belly pan. 23. Install the three front screws (4), the three rear screws (2) and push pin fasteners into the center of the belly pan. Rear Suspension INSTALLATION 1. Install the stabilizer bar and install the bushings and bolts (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6905 2. Tighten the bolts to 61 Nm (45 ft. lbs.). 3. Position the suspension knuckle assemblies back into position onto the crossmember. 4. Install the toe link cam bolts (1) at the cradle. 5. Tighten the bolts to 35 Nm (26 ft. lbs.). 6. Install the upper link bolts (2) at the cradle. 7. Tighten the bolts to 90 Nm (70 ft. lbs.). 8. Install the lower link bolts (5 and 6) at the cradle. 9. Tighten the bolts to 90 Nm (70 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6906 10. Install the stabilizer link nuts (2). 11. Tighten the nuts to 58 Nm (43 ft. lbs.). 12. Support the rear cradle assembly (1) with a suitable lifting device and position back into the vehicle. 13. Install the cradle bolts (2 and 3): a. Tighten the front bolt (2) first to 110 Nm (81 ft. lbs.). b. Tighten the rear bolt (3) next to 110 Nm (81 ft. lbs.). 14. Install the trailing link (1) bushing bolts (2 and 3): a. Tighten the inboard bolt (3) first to 110 Nm (81 ft. lbs.). b. Tighten the outboard bolt (2) next to 110 Nm (81 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6907 15. Install the lower strut bolts (1). 16. Tighten the bolts to 99 Nm 73 ft. lbs.). 17. Install the wheel speed sensor back, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Wheel Speed Sensor - Installation/Rear. 18. Position the brake lines (3) back into place, connect the clips (2) and install the bolts (1). 19. Tighten the bolts to 15 Nm (11 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6908 20. Position the brake lines (1) back into place, and install the bolts (2). 21. Tighten the bolts to 23 Nm (17 ft. lbs.). 22. Install the brake cable (2) onto the backing plate (3) and install the hair pin clip (1). 23. Connect the brake cable to the park brake lever. 24. Install the park brake shoes, See: Brakes and Traction Control/Parking Brake System/Parking Brake Shoe/Service and Repair/Installation. 25. Check and adjust wheel alignment as necessary, See: Maintenance/Alignment/Service and Repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Diagrams > Trailer Tow Lamp Relay (Trailer Tow) 4 Way Trailer Towing Relay: Diagrams Trailer Tow Lamp Relay (Trailer Tow) 4 Way Connector - (TRAILER TOW) 4 WAY RELAY-TRAILER TOW BRAKE LAMP - (TRAILER TOW) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Diagrams > Trailer Tow Lamp Relay (Trailer Tow) 4 Way > Page 6914 Trailer Towing Relay: Diagrams Left Trailer Tow Relay (Trailer Tow) 5 Way Connector - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW-LEFT - (TRAILER TOW) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Diagrams > Trailer Tow Lamp Relay (Trailer Tow) 4 Way > Page 6915 Trailer Towing Relay: Diagrams Right Trailer Tow Relay (Trailer Tow) 5 Way Connector - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW-RIGHT - (TRAILER TOW) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet - Removal Carpet: Service and Repair Carpet - Removal REMOVAL 1. Remove front seats. See: Seats/Service and Repair/Seat - Removal 2. Remove rear seats cushion. See: Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Removal 3. Remove rear seat back. See: Seats/Seat Back/Service and Repair/Removal and Replacement/Seat Back Removal 4. Remove cargo load floor. See: Trim Panel/Service and Repair/Cargo Floor Cover Removal 5. Remove center console. See: Console/Service and Repair/Center Console - Removal 6. Remove center console shifter housing.See: Console/Service and Repair/Center Console Removal 7. Remove lower B-Pillar trim. See: Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal 8. Remove door sill plate. See: Scuff Plate/Service and Repair/Scuff Plate Removal 9. Remove side cowl trim panel. See: Trim Panel/Service and Repair/Cowl Trim Panel Removal 10. Remove liftgate scuff plate. See: Scuff Plate/Service and Repair/Scuff Plate - Removal 11. Remove rear quarter trim.See: Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal 12. Remove carpet from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet - Removal > Page 6921 Carpet: Service and Repair Carpet - Installation INSTALLATION 1. Install carpet into vehicle ensuring carpet (1) is aligned with tabs (2). 2. Install rear quarter panel trim.See: Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel Installation 3. Install liftgate scuff plate. See: Scuff Plate/Service and Repair/Scuff Plate Installation 4. Install cargo load floor. See: Trim Panel/Service and Repair/Cargo Floor Cover Installation 5. Install side cowl trim panel. See: Trim Panel/Service and Repair/Cowl Trim Panel Installation 6. Install B-pillar lower trim. See: Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation 7. Install door sill scuff plate. See: Scuff Plate/Service and Repair/Scuff Plate Installation 8. Install center console.See: Console/Service and Repair/Center Console - Installation 9. Install center console shifter housing.See: Console/Service and Repair/Center Console Installation 10. Install rear seat cushion.See: Seats/Seat Cover/Service and Repair/Seat Cushion Cover Installation 11. Install rear seat back.See: Seats/Seat Back/Service and Repair/Removal and Replacement/Seat Back - Installation ) 12. Install front seats. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console - Removal Console: Service and Repair Center Console - Removal REMOVAL 1. Pull back on parking brake (5) to the upright position. 2. Open console door and remove two screws (1) fastening console to rear floor bracket (3). 3. Carefully pry up until the retainers (1) disengage from the center console to front floor bracket (6). 4. Disconnect center console wire connector (2) to instrument panel connector. 5. Remove from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Center Console - Removal > Page 6926 Console: Service and Repair Center Console - Installation INSTALLATION 1. Pull parking brake (5) into upright position. 2. Insert center console over parking brake. 3. Connect console wiring connector (2) to instrument panel connector (4). 4. Firmly seat the front of the center console retainers (1) until they engage to the front floor bracket (6). 5. Insert and fasten two rear screws (1) into rear floor bracket (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Glove Box - Removal Glove Compartment: Service and Repair Instrument Panel Glove Box - Removal Chill Zone(R) CHILL ZONE(R) 1. Open glove box cooler door (1). 2. Unsnap glove box cooler door from glove box door opening tabs (1). 3. Remove glove box cooler door from vehicle. Glove Box GLOVE BOX Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Glove Box - Removal > Page 6931 1. Open glove box latch. 2. Unsnap glove box damper from glove box bin. 3. Flex glove box open position stops (1) inboard and rotate past stops. 4. Unsnap glove box door from base panel lower hinge pins (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Glove Box - Removal > Page 6932 Glove Compartment: Service and Repair Instrument Panel Glove Box - Installation Chill Zone(R) CHILL ZONE(R) 1. Align cooler door with cooler door opening tabs (1). 2. Snap cooler door (1) on to door opening tabs. 3. Shut cooler door. Glove Box GLOVE BOX Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Glove Box - Removal > Page 6933 1. Align glove box door with glove box opening. 2. Snap glove box door hinge pins (2) to lower base panel hinges. 3. Flex glove box inboard and rotate inward past stops (1). 4. Close glove box. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headliner - Removal Headliner: Service and Repair Headliner - Removal REMOVAL 1. Remove front windshield.See: Windows and Glass/Windshield/Service and Repair/Windshield Removal 2. Remove A-pillar trim.See: Trim Panel/Service and Repair/Pillar Trim/A-Pillar Trim Panel-Removal 3. Disconnect A-pillar trim wire connector (2). 4. Remove sunvisors.See: Sun Visor/Service and Repair/Visor - Removal 5. Remove sun visor screws and retainers. See: Mirrors/Service and Repair/Interior Rearview Mirror - Installation 6. Disconnect front washer hose (1). 7. Remove universal homelink module and connector. See: Accessories and Optional Equipment/Garage Door Opener Transmitter/Service and Repair/Universal Transmitter - Removal. 8. Remove and disconnect dome lamp. See: Lighting and Horns/Dome Lamp/Service and Repair/Dome Lamp - Removal 9. Remove front and rear grab handles (3). 10. Remove seat belt turning loops. 11. Remove B-pillar upper trim.See: Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal 12. Remove B-pillar lower trim.See: Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal 13. Remove fastener attaching cargo loop to rear quarter trim. 14. Remove rear seat striker bezel. 15. Remove C-pillar trim.See: Trim Panel/Service and Repair/Pillar Trim/C-Pillar Trim Panel-Removal 16. Remove rear quarter trim.See: Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel Removal 17. Remove cargo load floor.See: Trim Panel/Service and Repair/Cargo Floor Cover Removal 18. Remove liftgate scuff plate.See: Scuff Plate/Service and Repair/Scuff Plate - Removal 19. Remove rear cargo dome light and disconnect connector. See: Lighting and Horns/Dome Lamp/Service and Repair/Dome Lamp - Removal 20. Remove rear headliner push pins. 21. Disconnect rear washer hose connector Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headliner - Removal > Page 6938 22. Lower headliner. 23. With the help of an assistant, remove headliner through front windshield opening. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headliner - Removal > Page 6939 Headliner: Service and Repair Headliner - Installation INSTALLATION 1. Before headliner installation, install courtesy lamp, cargo lamp, and Universal transmitter module to headliner. See: Accessories and Optional Equipment/Garage Door Opener Transmitter/Service and Repair/Universal Transmitter Installation. 2. With the help of an assistant, Install headliner through windshield opening. 3. Connect rear cargo lamp connector. See: Lighting and Horns/Cargo Lamp/Service and Repair/Removal and Replacement/Cargo Lamp Installation 4. Install headliner push pins located at rear of headliner. 5. Connect front dome lamp connector. See: Lighting and Horns/Dome Lamp/Service and Repair/Dome Lamp - Installation 6. If equipped, connect home link module connector. See: Accessories and Optional Equipment/Garage Door Opener Transmitter/Service and Repair/Universal Transmitter - Installation. 7. Connect front rear view mirror hardware.See: Mirrors/Service and Repair/Interior Rearview Mirror - Installation 8. Install rear view mirror.See: Mirrors/Service and Repair/Interior Rearview Mirror - Installation 9. Install grab handles (3). 10. Connect rear washer hose. 11. Install sunvisor retainers. See: Mirrors/Service and Repair/Interior Rearview Mirror - Installation 12. Install sun visors. 13. Connect A-pillar wire connector. 14. Install A-pillar trim.See: Trim Panel/Service and Repair/Pillar Trim/A-Pillar Trim Panel-Installation 15. Install scuff plate. See: Scuff Plate/Service and Repair/Scuff Plate - Installation 16. Install B-pillar lower trim.See: Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation 17. Install B-pillar upper trim.See: Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation 18. Install cargo load floor. See: Trim Panel/Service and Repair/Cargo Floor Cover - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headliner - Removal > Page 6940 19. Install rear quarter trim.See: Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation 20. Install C-pillar trim. See: Trim Panel/Service and Repair/Pillar Trim/C-Pillar Trim Panel-Installation 21. Install rear seat striker bezel. 22. Install seat belt turning loops. 23. Install rear cargo scuff plate. See: Mirrors/Service and Repair/Interior Rearview Mirror - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Scuff Plate - Removal Scuff Plate: Service and Repair Scuff Plate - Removal Door Sill REMOVAL 1. Using trim stick C-4755, pry up scuff plate. 2. Remove scuff plate from vehicle. Liftgate Sill REMOVAL 1. Using trim stick C-4755 or equivalent, pry up on each scuff plate clip location hole (2). 2. Remove scuff plate (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Scuff Plate - Removal > Page 6945 Scuff Plate: Service and Repair Scuff Plate - Installation Door Sill INSTALLATION 1. Place scuff plate (1) onto door sill (2). 2. Align scuff plate tabs with door scuff holes. 3. Hand press scuff plate ensuring tabs are properly seated. Liftgate Sill INSTALLATION 1. Locate trim clips and align metal clips to liftgate inner. 2. Tap on panel at each trim clip location (2) until properly seated. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Visor Support - Removal Sun Visor: Service and Repair Visor Support - Removal REMOVAL 1. Disengage the sun visor (1) from the sun visor support (2). 2. Remove the screw that secures the support to the roof panel and remove the support from the headliner (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Visor Support - Removal > Page 6950 Sun Visor: Service and Repair Visor Support - Installation INSTALLATION 1. Position the sun visor support (2) on the headliner (3) and install the screw that secures the support to the roof panel. 2. Engage the sun visor (1) and sun visor support. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Visor Support - Removal > Page 6951 Sun Visor: Service and Repair Visor - Removal REMOVAL 1. Disengage the sun visor (2) from the sun visor support. 2. Remove the two screws that secure the sun visor to the roof panel and remove the sun visor from the headliner (1). 3. If equipped, disconnect the illuminated vanity mirror wire harness connector. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Visor Support - Removal > Page 6952 Sun Visor: Service and Repair Visor - Installation INSTALLATION 1. If equipped, connect the illuminated vanity mirror wire harness connector. 2. Position the sun visor (2) on the headliner (1) and install the two screws that secure the sun visor to the roof panel. 3. Engage the sun visor and sun visor support. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal Trim Panel: Service and Repair Cargo Floor Cover - Removal REMOVAL 1. Pull upward on cargo load floor (1) disengaging tabs. 2. Pull outward at rear of cargo load floor removing cargo load floor disengaging cargo load floor from rear quarter panel pockets. 3. Remove from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal > Page 6957 Trim Panel: Service and Repair Cargo Floor Cover - Installation INSTALLATION 1. Load cargo load floor (1) into vehicle, ensuring cargo load floor pivots fit into pockets onto the rear quarter trim panel. 2. Once rear cargo load floor pivots are properly seated into pockets, snap down the front cargo load floor tabs ensuring cargo load floor is seated. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal > Page 6958 Trim Panel: Service and Repair Cowl Trim Panel - Removal REMOVAL NOTE: Left hand shown, right side similar. 1. Remove door sill scuff plate.See: Scuff Plate/Service and Repair/Scuff Plate - Removal 2. Remove nut (3) securing trim (1) to dash. 3. Using trim stick C-4755, pry up on cowl trim and remove from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal > Page 6959 Trim Panel: Service and Repair Cowl Trim Panel - Installation INSTALLATION 1. Place tab cowl trim (1) over stud on dash and wrap door flange. 2. Align hole for park brake release handle and clip on trim to hole (2) in cowl side. 3. Install nut (3) and fasten until cowl trim is seated. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal > Page 6960 Trim Panel: Service and Repair Cargo Floor Cover - Removal REMOVAL 1. Pull upward on cargo load floor (1) disengaging tabs. 2. Pull outward at rear of cargo load floor removing cargo load floor disengaging cargo load floor from rear quarter panel pockets. 3. Remove from vehicle. Cargo Floor Cover - Installation INSTALLATION 1. Load cargo load floor (1) into vehicle, ensuring cargo load floor pivots fit into pockets onto the rear quarter trim panel. 2. Once rear cargo load floor pivots are properly seated into pockets, snap down the front cargo load floor tabs ensuring cargo load floor is seated. Cowl Trim Panel - Removal REMOVAL NOTE: Left hand shown, right side similar. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal > Page 6961 1. Remove door sill scuff plate.See: Scuff Plate/Service and Repair/Scuff Plate - Removal 2. Remove nut (3) securing trim (1) to dash. 3. Using trim stick C-4755, pry up on cowl trim and remove from vehicle. Cowl Trim Panel - Installation INSTALLATION 1. Place tab cowl trim (1) over stud on dash and wrap door flange. 2. Align hole for park brake release handle and clip on trim to hole (2) in cowl side. 3. Install nut (3) and fasten until cowl trim is seated. Quarter Trim Panel - Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal > Page 6962 1. Remove the rear quarter trim cargo loop (2) retaining screw. NOTE: If removing the right side lower quarter trim panel, remove the sub woofer (if equipped) See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Speaker - Removal . 2. Remove cargo floor See: Cargo Floor Cover - Removal. 3. Remove liftgate scuff plate See: Scuff Plate/Service and Repair/Scuff Plate - Removal. 4. Remove B-pillar lower trim See: Pillar Trim/B-Pillar Trim Panel-Removal. 5. Remove the door sill scuff plate See: Scuff Plate/Service and Repair/Scuff Plate - Removal. 6. Remove the upper C-pillar trim See: Pillar Trim/C-Pillar Trim Panel-Removal. 7. Remove the rear quarter panel trim (4). Quarter Trim Panel - Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal > Page 6963 1. Position the rear quarter panel trim (4) over the retaining slots and firmly snap into place. 2. Install the door sill scuff plate See: Scuff Plate/Service and Repair/Scuff Plate - Installation. 3. Install the B-pillar lower trim See: Pillar Trim/B-Pillar Trim Panel-Installation. 4. Install the upper C-pillar trim See: Pillar Trim/C-Pillar Trim Panel-Installation. 5. Install the liftgate scuff plate See: Scuff Plate/Service and Repair/Scuff Plate - Installation. 6. Install the cargo floor See: Cargo Floor Cover - Installation. NOTE: If equipped with a sub woofer, install at this time See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Speaker - Installation . 7. Install the cargo loop (2) and screw. A-Pillar Trim Panel-Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal > Page 6964 1. Using special tool C-4755, remove plug (1) from A-pillar. 2. Remove screw. 3. Remove A-pillar trim. A-Pillar Trim Panel-Installation INSTALLATION 1. Insert A-Pillar trim bottom first ensuring trim has seated into clips. 2. Install screw. NOTE: It is very important to insert small tab of plug into small trim opening. 3. Insert plug bottom first (2) into trim opening. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal > Page 6965 4. Hinge A-pillar plug upward ensuring proper seat. B-Pillar Trim Panel INSTALLATION 1. Install B-pillar (1) trim to B-pillar (5) by inserting B-pillar trim tab (2) into B-pillar slot. 2. Push B-pillar trim into position ensuring bottom clip (4) has seated. 3. Add screw (3) and reinstall plug. B-Pillar Trim Lower Panel INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal > Page 6966 1. Insert lower tabs on B-pillar lower trim (1) onto sill panel. 2. Hand tap on clip locations ensuring clips are properly seated. B-Pillar Trim Panel REMOVAL 1. Remove lower B-pillar trim from B-pillar (5). 2. Remove plug. 3. Remove screw (3). 4. Remove trim (1) by pulling tab (2) on top outward. B-Pillar Trim Lower Panel REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal > Page 6967 1. Using special tool C-4755, pry off B-pillar lower trim. 2. Remove from vehicle. C-Pillar Trim Panel-Removal REMOVAL 1. Remove lower quarter. 2. Remove lower seat anchors from seat belt opening (1). 3. Remove upper quarter by pulling on rear portion of upper quarter disengaging clips from metal holes in body (4). 4. Remove front lower portion (3) by pulling clip loose. 5. Slide quarter panel (2) downward and remove from vehicle. C-Pillar Trim Panel-Installation INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal > Page 6968 1. Pass seat belt anchors through trim openings (1). 2. Install quarter trim (2) by sliding hook at top and locating 4-way locator into the body side sheet metal holes (4). 3. Complete installation by aligning metal clips and snaping until properly seated. Automatic REMOVAL 1. Pull up on shifter knob (1) and remove. 2. Using trim stick C-4755 or equivalent, pry up on bezel (2) and remove from shifter pod (3). Manual REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal > Page 6969 1. Pull up on shifter knob (3) and remove. 2. Using trim stick C-4755 or equivalent, pry up on bezel (1) and remove from shifter pod (4). Automatic INSTALLATION 1. Insert bezel (2) locator to shifter pod (3). 2. Apply hand pressure until clips are seated. 3. Snap shifter knob (1) onto shifter shaft. 4. Pull up on knob (1) to verify seated correctly. Manual INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal > Page 6970 1. Locate bezel (1) over shifter lever (5) and into shifter pod (4). 2. Insert bezel locator to shifter pod (4). 3. Apply hand pressure to bezel (1) until clips are seated. 4. Slide boot (2) over shift lever (5) to bezel (1). 5. Apply hand pressure to snap bottom of boot (2) into bezel (1). 6. Snap shifter knob (3) onto shifter lever (5). 7. Pull up on know to verify seated correctly. Shifter Housing - Removal REMOVAL 1. Remove shift knob and shift bezel.See: Shifter Bezel - Removal See: Shifter Bezel - Removal 2. Remove two screws (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal > Page 6971 3. Pull on side of housing (1) and unsnap housing tabs. 4. Disconnect console housing wire connector (2) and instrument panel connector (3). 5. Remove from vehicle. Shifter Housing - Installation INSTALLATION 1. Connect center console housing wire connector (2) with instrument panel connector (3). 2. Place console housing (1) over shifter lever ensuring console tabs seat properly. 3. Install screws (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cargo Floor Cover - Removal > Page 6972 4. Replace shift bezel and knob. See: Shifter Bezel - Installation See: Shifter Bezel - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6978 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY MODULE-SENTRY KEY REMOTE ENTRY/WCM - (INSTRUMENT PANEL) 8 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Keyless Entry Module: Initial Inspection and Diagnostic Overview REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic information. Refer to the appropriate wiring information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6981 Keyless Entry Module: Programming and Relearning SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6982 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal Keyless Entry Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Removal REMOVAL NOTE: The steering wheel does not have to be removed to service the SKREEM/WCM. NOTE: The Steering Column Control Module (SCCM) assembly, which consists of the left/right multi-function switches and the clockspring, does not have to be removed to service the SKREEM/WCM. There is an access hole in the top of the right multi-function switch to access the mounting screw (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the upper and lower steering column shrouds See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the SKREEM/WCM mounting screw (2) on the ignition lock assembly and separate the SKREEM/WCM (3) from the ignition lock assembly. 4. Disconnect the SKREEM/WCM electrical connector (4). 5. Remove SKREEM/WCM (1 and 3) from column (2). When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Testing and Inspection/Programming and Relearning. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 6985 - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 6986 Keyless Entry Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Installation INSTALLATION When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Testing and Inspection/Programming and Relearning. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. 1. Position the SKREEM/WCM (3) on the ignition lock housing and install the retaining screw (2). 2. Connect the SKREEM/WCM electrical connector (4). NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated . See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Alarm System Transponder/Testing and Inspection 3. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair RKE TRANSMITTER BATTERIES The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves near the key ring until the two halves unsnap. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the two batteries with new Panasonic 2016, or equivalent. Be certain that the batteries are installed with their polarity correctly oriented. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together until they snap back into place. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Front Door Latch Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Front Door Latch > Page 6996 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (LHD Base) (Left Front Door) 4 Way Power Door Lock Actuator: Diagrams Driver Door Latch (LHD Base) (Left Front Door) 4 Way Connector (LHD BASE) - (LEFT FRONT DOOR) 4 WAY LATCH-DOOR-DRIVER (LHD BASE) - (LEFT FRONT DOOR) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (LHD Base) (Left Front Door) 4 Way > Page 6999 Power Door Lock Actuator: Diagrams Driver Door Latch (LHD Except Base) (Left Front Door) 4 Way Connector (LHD EXCEPT BASE) - (LEFT FRONT DOOR) 4 WAY LATCH-DOOR-DRIVER (LHD EXCEPT BASE) - (LEFT FRONT DOOR) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (LHD Base) (Left Front Door) 4 Way > Page 7000 Power Door Lock Actuator: Diagrams Left Rear Door Latch (LHD Base) (Left Rear Door) 4 Way Connector (LHD BASE) - (LEFT REAR DOOR) 4 WAY LATCH-DOOR-LEFT REAR (LHD BASE) - (LEFT REAR DOOR) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (LHD Base) (Left Front Door) 4 Way > Page 7001 Power Door Lock Actuator: Diagrams Left Rear Door Latch (LHD Except Base) (Left Rear Door) 4 Way Connector (LHD EXCEPT BASE) - (LEFT REAR DOOR) 4 WAY LATCH-DOOR-LEFT REAR (LHD EXCEPT BASE) - (LEFT REAR DOOR) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (LHD Base) (Left Front Door) 4 Way > Page 7002 Power Door Lock Actuator: Diagrams Driver Door Latch (LHD Base) (Left Front Door) 4 Way Connector (LHD BASE) - (LEFT FRONT DOOR) 4 WAY LATCH-DOOR-DRIVER (LHD BASE) - (LEFT FRONT DOOR) 4 WAY Driver Door Latch (LHD Except Base) (Left Front Door) 4 Way Connector (LHD EXCEPT BASE) - (LEFT FRONT DOOR) 4 WAY LATCH-DOOR-DRIVER (LHD EXCEPT BASE) - (LEFT FRONT DOOR) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (LHD Base) (Left Front Door) 4 Way > Page 7003 Left Rear Door Latch (LHD Base) (Left Rear Door) 4 Way Connector (LHD BASE) - (LEFT REAR DOOR) 4 WAY LATCH-DOOR-LEFT REAR (LHD BASE) - (LEFT REAR DOOR) 4 WAY Left Rear Door Latch (LHD Except Base) (Left Rear Door) 4 Way Connector (LHD EXCEPT BASE) - (LEFT REAR DOOR) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (LHD Base) (Left Front Door) 4 Way > Page 7004 LATCH-DOOR-LEFT REAR (LHD EXCEPT BASE) - (LEFT REAR DOOR) 4 WAY Passenger Door Latch (LHD Base) (Right Front Door) 4 Way Connector (LHD BASE) - (RIGHT FRONT DOOR) 4 WAY LATCH-DOOR-PASSENGER (LHD BASE) - (RIGHT FRONT DOOR) 4 WAY Passenger Door Latch (LHD Except Base) (Right Front Door) 4 Way Connector (LHD EXCEPT BASE) - (RIGHT FRONT DOOR) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (LHD Base) (Left Front Door) 4 Way > Page 7005 LATCH-DOOR-PASSENGER (LHD EXCEPT BASE) - (RIGHT FRONT DOOR) 4 WAY Right Rear Door Latch (LHD Base) (Right Rear Door) 4 Way Connector (LHD BASE) - (RIGHT REAR DOOR) 4 WAY LATCH-DOOR-RIGHT REAR (LHD BASE) - (RIGHT REAR DOOR) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Driver Door Latch (LHD Base) (Left Front Door) 4 Way > Page 7006 Right Rear Door Latch (LHD Except Base) (Right Rear Door) 4 Way Connector (LHD EXCEPT BASE) - (RIGHT REAR DOOR) 4 WAY LATCH-DOOR-RIGHT REAR (LHD EXCEPT BASE) - (RIGHT REAR DOOR) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Door Lock Motor - Description Power Door Lock Actuator: Description and Operation Door Lock Motor - Description DESCRIPTION The lock mechanisms are actuated by a reversible electric motor mounted within each door and tailgate. The power lock motors are integral to the door latch units. The power lock motors cannot be adjusted or repaired and, if inoperative or damaged, the door latch unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Door Lock Motor - Description > Page 7009 Power Door Lock Actuator: Description and Operation Door Lock Motor - Operation OPERATION The door lock motors are controlled by relays. A positive and negative battery connection to the two motor terminals will cause the motor to move in one direction. Reversing the current will cause the motor to move in the opposite direction. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Page 7010 Power Door Lock Actuator: Testing and Inspection DOOR LOCK MOTOR The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic information. Refer to the appropriate wiring information. 1. Make certain battery is in normal condition and fuses powering the RKE module aren't blown before circuits are tested. 2. To determine which motor is inoperative, check each individual door for electrical lock and unlock or disconnect the motor connectors one at a time, while operating the door lock switch. 3. In the event that none of the motors work, the problem maybe caused by a shorted motor, a bad switch or a bad relay internal to the RKE module. Disconnecting a defective motor will allow the others to work. 4. To test an individual door lock motor, disconnect the electrical connector from the motor. 5. To lock the door, connect a 12 volt power source to one pin of the lock motor and a ground wire to the other pin. 6. To unlock the door, reverse the wire connections at the motor pin terminals. 7. If these results are NOT obtained, replace the motor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Liftgate Door Lock Motor - Removal Power Door Lock Actuator: Service and Repair Liftgate Door Lock Motor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove liftgate trim panel. 3. Disconnect motor wire harness connector. 4. Remove liftgate lock motor (2) from liftgate by gently unsnapping. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Liftgate Door Lock Motor - Removal > Page 7013 Power Door Lock Actuator: Service and Repair Liftgate Door Lock Motor - Installation INSTALLATION 1. Install liftgate lock motor (2) on the liftgate. 2. Install motor wire harness connector. 3. Install the liftgate trim panel. 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection Power Door Lock Switch: Testing and Inspection DOOR LOCK SWITCH 1. Remove the switch. 2. Using an ohmmeter, refer to Door Lock Switch Test table to determine if switch resistance is correct in the Lock and Unlock switch positions. Refer to Wiring Diagrams for harness connector pin-outs. DOOR LOCK SWITCH TEST Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal Power Door Lock Switch: Service and Repair Power Lock Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Removal. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal > Page 7019 Power Door Lock Switch: Service and Repair Power Lock Switch - Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Installation 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7024 Power Mirror Switch: Diagrams Connector (LHD) - (LEFT FRONT DOOR) 10 WAY SWITCH-MIRROR (LHD) - (LEFT FRONT DOOR) 10 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7025 Power Mirror Switch: Testing and Inspection POWER MIRROR SWITCH - LHD 1. Disconnect and isolate the battery negative cable. 2. Remove power mirror switch See: Service and Repair/Power Mirror Switch - Removal. 3. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Test table. 4. If test results are not obtained as shown in the Mirror Switch Test table, replace the switch. MIRROR SWITCH TEST TABLE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7026 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch - Removal Power Mirror Switch: Service and Repair Power Mirror Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Removal. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch - Removal > Page 7029 Power Mirror Switch: Service and Repair Power Mirror Switch - Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Installation 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes DODGE CALIBER PAINT CODES Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 7035 Paint: Application and ID Paint Code Location DODGE CALIBER PAINT CODE LOCATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Description and Operation > Basecoat/Clearcoat Finish - Description Paint: Description and Operation Basecoat/Clearcoat Finish - Description DESCRIPTION On most vehicles a two-part paint application (basecoat/clearcoat) is used. Color paint that is applied to primer is called basecoat. The clearcoat protects the basecoat from ultraviolet light and provides a durable high-gloss finish. CAUTION: Do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result. Do not use harsh alkaline based cleaning solvents on painted surfaces. Damage to finish or color can result. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up Paint: Service and Repair Paint Touch-Up DESCRIPTION When a painted metal surface has been scratched or chipped, it should be touched up as soon as possible to avoid corrosion. For best results, use Mopar(R) Scratch Filler/Primer, Touch Up Paints and Clear Top Coat. For a description of the paint codes, See: Application and ID. WARNING: Use an OSHA approved respirator and safety glasses when spraying paint or solvents in a confined area. Personal injury can result. TOUCH UP PROCEDURE 1. Scrape loose paint and corrosion from inside scratch or chip. 2. Clean affected area with Mopar(R) Tar/Road Oil Remover, and allow to dry. 3. Fill the inside of the scratch or chip with a coat of filler/primer. Do not overlap primer onto good surface finish. The applicator brush should be wet enough to puddle-fill the scratch or chip without running. Do not stroke brush applicator on body surface. Allow the filler/primer to dry hard. 4. Cover the filler/primer with color touch up paint. Do not overlap touch up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch up paint to dry hard. 5. On vehicles without clearcoat, the touch up color can be lightly finesse sanded (1500 grit) and polished with rubbing compound. 6. On vehicles with clearcoat, apply clear top coat to touch up paint with the same technique as described in 4. Allow clear top coat to dry hard. If desired, 5 can be performed on clear top coat. WARNING: Avoid prolonged skin contact with petroleum or alcohol - based cleaning solvents. Personal injury can result. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up > Page 7040 Paint: Service and Repair Finesse Sanding, Buffing, And Polishing - Description DESCRIPTION Minor acid etching, orange peel, or smudging in clearcoat or single-stage finishes can be reduced with light finesse sanding, hand buffing, and polishing. If the finish has been finesse sanded in the past, it cannot be repeated. Finesse sanding operation should be performed by a trained automotive paint technician. CAUTION: Do not remove clearcoat finish, if equipped. Basecoat paint must retain clearcoat for durability. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 7045 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY MODULE-SENTRY KEY REMOTE ENTRY/WCM - (INSTRUMENT PANEL) 8 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Keyless Entry Module: Initial Inspection and Diagnostic Overview REMOTE KEYLESS ENTRY MODULE The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic information. Refer to the appropriate wiring information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7048 Keyless Entry Module: Programming and Relearning SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7049 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal Keyless Entry Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Removal REMOVAL NOTE: The steering wheel does not have to be removed to service the SKREEM/WCM. NOTE: The Steering Column Control Module (SCCM) assembly, which consists of the left/right multi-function switches and the clockspring, does not have to be removed to service the SKREEM/WCM. There is an access hole in the top of the right multi-function switch to access the mounting screw (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the upper and lower steering column shrouds See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the SKREEM/WCM mounting screw (2) on the ignition lock assembly and separate the SKREEM/WCM (3) from the ignition lock assembly. 4. Disconnect the SKREEM/WCM electrical connector (4). 5. Remove SKREEM/WCM (1 and 3) from column (2). When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Testing and Inspection/Programming and Relearning. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 7052 - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 7053 Keyless Entry Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Installation INSTALLATION When a PCM and the SKREEM/WCM are replaced at the same time, perform the following steps in order See: Testing and Inspection/Programming and Relearning. - Program the new PCM. - Program the new SKREEM/WCM. - Replace all ignition keys and program them to the new SKREEM/WCM. 1. Position the SKREEM/WCM (3) on the ignition lock housing and install the retaining screw (2). 2. Connect the SKREEM/WCM electrical connector (4). NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated . See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Alarm System Transponder/Testing and Inspection 3. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 7057 Seat Heater Control Module: Diagrams Connector - (DRIVER SEAT) 10 WAY MODULE-HEATED SEATS - (DRIVER SEAT) 10 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description Seat Heater Control Module: Description and Operation Heated Seat Module - Description DESCRIPTION The heated seat module (2) is located under the left front seat. It has a single electrical connector (1) and a push pin style retainer that secures it to the seat pan. The module can be accessed from under the front left seat with the seat in the full back position. The heated seat module is a microprocessor designed to use the Local Interface Network (LIN) data bus messages from the instrument cluster also known as the Cabin Compartment Node (CCN). The CCN receives inputs from the heated seat switches and in turn signals the heated seat module to operate the heated seat elements for both front seats. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description > Page 7060 Seat Heater Control Module: Description and Operation Heated Seat Module - Operation OPERATION The heated seat module operates on fused battery current received from the ignition switch. The module is grounded to the body at all times through the electrical connector. Inputs to the module include Local Interface Network (LIN) data bus messages and standard hardwired 12 volt power and ground. In response to the LIN inputs the heated seat module will control the battery current to the appropriate heated seat elements. When a heated seat switch LIN data bus signal is received by the heated seat module, the module energizes the selected heated seat element. The Low heat set point is about 38° C (100.4° F), and the High heat set point is about 42° C (107.6° F). In addition to operating the heated seat elements, the heated seat module sends LED illumination messages to the CCN via the LIN data bus. The CCN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. If the heated seat module detects a heated seat element OPEN or SHORT circuit, it will record and store the appropriate diagnostic trouble code (DTC). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 7061 Seat Heater Control Module: Testing and Inspection HEATED SEAT MODULE In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal Seat Heater Control Module: Service and Repair Heated Seat Module - Removal REMOVAL CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Position the left front seat to the full rearward position. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the wire harness connector (4) from the heated seat module (3). 4. Unsnap the heated seat module retaining tab (2) from the seat pan (1). 5. Remove the heated seat module (3) from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal > Page 7064 Seat Heater Control Module: Service and Repair Heated Seat Module - Installation INSTALLATION CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Install the heated seat module (3) into the vehicle. 2. Position the retaining tab (2) with the mounting hole in the seat pan (1). Firmly apply even pressure to the module (3) until the mounting tab is fully seated. 3. Connect the wire harness connector (4) to the heated seat module (3). 4. Connect the battery negative cable. 5. Check for proper heated seat system operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Trailer Tow Lamp Relay (Trailer Tow) 4 Way Trailer Towing Relay: Diagrams Trailer Tow Lamp Relay (Trailer Tow) 4 Way Connector - (TRAILER TOW) 4 WAY RELAY-TRAILER TOW BRAKE LAMP - (TRAILER TOW) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Trailer Tow Lamp Relay (Trailer Tow) 4 Way > Page 7070 Trailer Towing Relay: Diagrams Left Trailer Tow Relay (Trailer Tow) 5 Way Connector - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW-LEFT - (TRAILER TOW) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Trailer Tow Lamp Relay (Trailer Tow) 4 Way > Page 7071 Trailer Towing Relay: Diagrams Right Trailer Tow Relay (Trailer Tow) 5 Way Connector - (TRAILER TOW) 5 WAY RELAY-TRAILER TOW-RIGHT - (TRAILER TOW) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade - Removal Sun Shade: Service and Repair Sunroof Sunshade - Removal REMOVAL 1. Remove the drain trough, See: Sunroof / Moonroof Track/Service and Repair/Sunroof Trough Removal 2. Push up the front center of the sunshade (1) to pop out the front two feet. 3. Rotate the sunshade (2) so that the other feet (1) are removed from the guide track. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade - Removal > Page 7078 Sun Shade: Service and Repair Sunroof Sunshade - Installation INSTALLATION 1. Verify the sunshade track is free of obstructions like the trim lace/ring. 2. Start with sunshade (2) at an angle with one foot (1) in the track. 3. Rotate the sunshade so the other rear foot is in the track as well as the 2 other feet (3) on the same side as the first foot. 4. To insert the remaining two feet (2) apply force to the middle front of sunshade (3) and guide them into the track. 5. Check that all the feet are in the right track and verify sunshade operation. 6. Install the drain trough, See: Sunroof / Moonroof Track/Service and Repair/Sunroof Trough Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 7082 Sunroof / Moonroof Motor: Diagrams Connector - (A-PILLAR JUMPER) 10 WAY MOTOR-SUNROOF - (A-PILLAR JUMPER) 10 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 7083 Sunroof / Moonroof Motor: Testing and Inspection DRIVE MOTOR TEACH PROCEDURE REPLACEMENT DRIVE MOTOR 1. Upon first powering up the sunroof, continuously press the close button on the power sunroof switch. The sunroof will begin moving in the tilt up direction. 2. The glass panel will move to the hard stop (just past the full tilt position) and then reverse to the soft stop (the full tilt position). 3. Once the sunroof has reversed immediately (within 5 seconds of stopping travel), release the switch and continuously press the close button again. 4. The sunroof glass will continue to move to the fully closed position. Once fully closed the close button can be released. ORIGINAL DRIVE MOTOR 1. Cycle the sunroof to full close position and release close button on the power sunroof switch. 2. Once the sunroof is in the fully closed position, press and continuously hold the close button again. 3. After a ten second delay the sunroof will begin to move past the normal vent position to the hard stop position. It will then reverse to the normal full vent position (also called the soft stop). 4. Once the sunroof has reversed to the vent soft stop, immediately (within 5 seconds of stopping travel) release the close button and continuously press it again. 5. After a three second delay the sunroof glass will continue to move to the fully closed position. Once fully closed the close button can be released. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Sunroof Motor - Removal Sunroof / Moonroof Motor: Service and Repair Sunroof Motor - Removal REMOVAL 1. Remove headliner. See: Interior Moulding / Trim/Headliner/Service and Repair/Headliner Removal 2. Disconnect the electrical connector (1). 3. Remove three motor assembly attaching screws (4) from bottom side of motor assembly (3) and remove motor assembly from the motor bracket. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Sunroof Motor - Removal > Page 7086 Sunroof / Moonroof Motor: Service and Repair Sunroof Motor - Installation INSTALLATION 1. If sunroof was open when drive motor was removed, carefully move glass panel into closed position and remove glass panel. See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass - Removal 2. Set lifter arm timing by manually sliding the mechanisms (1) in the track until timing holes in the trollies are aligned with the timing holes in the lifter arm cams (2) and insert pins (3) into the mechanisms to hold mechanisms in closed position. 3. Place motor (3) into position and install screws (4) attaching motor to bracket (2). 4. Tighten the screws (4) to 3 Nm (26 in. lbs.). 5. If sunroof glass panel was removed previously, remove the timing pins and install the sunroof glass panel. See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass - Installation 6. Partially install the headliner and connect the sunroof wiring electrical connectors. See: Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation 7. Temporarily install sunroof switch and perform the sunroof motor teach procedure. See: Testing and Inspection. 8. Test sunroof operation, adjust glass as necessary. See: Sunroof / Moonroof Panel/Adjustments 9. Complete the headliner installation. See: Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Description and Operation > Sunroof Switch - Description Sunroof / Moonroof Switch: Description and Operation Sunroof Switch - Description DESCRIPTION The power sunroof switch (2) is a combination push-button and rocker switch module mounted in the Courtesy/Reading Lamp assembly (1). The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof express open (back of switch pushed and released) - Power sunroof closed (front of switch pushed) - Power sunroof express closed (front of switch pushed and released) - Power sunroof vent (switch center button pushed) The power sunroof switch cannot be repaired. If the individual components are damaged or inoperative the switch assembly must be replaced, See: Service and Repair/Sunroof Switch Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Description and Operation > Sunroof Switch - Description > Page 7091 Sunroof / Moonroof Switch: Description and Operation Sunroof Switch - Operation OPERATION The sunroof is electrically operated from two switches located in the headliner on the courtesy/reading lamp assembly. The power sunroof switch is hard wired to the sunroof motor/module assembly. The "VENT" switch is a push button type switch and opens the sunroof to the vent position only. The other switch "OPEN/CLOSED" is a rocker type switch for opening and closing the sunroof. Pressing and releasing the open button once, the sunroof will express open and the wind deflector will raise. If the button is pressed a second time the sunroof will stop in that position. Pressing and releasing the close button once will express close the sunroof. If the close button is pressed a second time during the express close operation the sunroof will stop in that position. The switch is grounded at one terminal and receives a 5 volt signal from the sunroof motor/module on the remaining three terminals. The switch pulls down the 5 volt reference voltage from the module signaling it to perform the desired function. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Description and Operation > Page 7092 Sunroof / Moonroof Switch: Testing and Inspection SUNROOF SWITCH For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the power sunroof switch, See: Service and Repair/Sunroof Switch - Removal. 2. Disconnect the power sunroof switch wire harness connector. 3. With the ignition key in the "RUN" position check for 5 volts on the "OPEN", "CLOSE" and "VENT" circuits of the sunroof switch harness connector. If OK, go to 4. If not OK, inspect the wiring harness and connectors between the motor/module and switch for damage and repair as necessary. 4. With the ignition key in the "OFF" position check for continuity between the ground circuit of the sunroof switch harness connector and a known good ground. Continuity should be present. If OK, go to 5. If not OK, inspect the wiring harness and connector and repair the ground circuit as necessary. 5. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage and repair as necessary. If not OK, replace the power sunroof switch, See: Service and Repair/Sunroof Switch Removal. POWER SUNROOF SWITCH CONTINUITY TABLE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch - Removal Sunroof / Moonroof Switch: Service and Repair Sunroof Switch - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the courtesy/reading lamp lens (5). Insert a suitable flat bladed tool into the slot (6) in the courtesy/reading lamp assembly (2). Pivot the lens down and to the left to release the holding tab (4). 3. Using a suitable flat bladed tool, release the mounting tabs (5) from the sides of the sunroof control switch (4) and pull the switch down from the courtesy/reading lamp assembly (2). 4. Disconnect the electrical connector (3) from the sunroof control switch (4). 5. Remove the switch from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch - Removal > Page 7095 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch - Installation INSTALLATION 1. Position the sunroof control switch (4) into the vehicle. 2. Connect the sunroof control switch electrical connector (3). 3. Insert the sunroof control switch (4) into the courtesy/reading lamp assembly (2). Push up on the switch until it is securely held in place by the mounting tabs (5). 4. Insert the mounting tab (4) on the lamp lens (5) into the right side of the lamp assembly and pivot the lens up until it snaps securely in place. 5. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Sunroof Trough - Removal Sunroof / Moonroof Track: Service and Repair Sunroof Trough - Removal REMOVAL 1. Remove the glass See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass - Removal. 2. Separate the trough pins (3) from the glass lift mechanisms (1). 3. Slide trough (1) to one side and push down on the center of the trough until the guide shoe tab (3) releases from the track (2). 4. Slide the trough in the opposite direction to release the other shoe and lift the trough out of the sunroof opening. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Sunroof Trough - Removal > Page 7100 Sunroof / Moonroof Track: Service and Repair Sunroof Trough - Installation INSTALLATION 1. Insert one of the trough guides (3) and guide shoe (2) into the track. 2. Push down on the center of the trough (1) to flatten it out and install the remaining trough guide (3) and guide shoe (2) into the track. 3. Install the trough guide pins into the glass lift mechanism (3) and seat fully. 4. Install the glass See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Wind Deflector - Removal Sunroof / Moonroof Windguard: Service and Repair Wind Deflector - Removal REMOVAL 1. Open the sunroof glass to the full open position. 2. Press the spring lock (1) with a small flat bladed tool and push the wind deflector (2) reward to release from the car top opening. 3. Repeat the previous step on the opposite side. 4. Rotate the wind deflector (1) up and release from the mounting hole (2) in the sunroof frame. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Wind Deflector - Removal > Page 7105 Sunroof / Moonroof Windguard: Service and Repair Wind Deflector - Installation INSTALLATION 1. Position the wind deflector springs (1) into the mounting holes (2) in the sunroof frame. 2. Rotate forward and down into position. 3. Slide the wind deflector and spring (1) forward under the car top lip and make sure the spring lock snaps into place (2) fully. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Tube - Removal Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Tube - Removal REMOVAL 1. Drop down the headliner as necessary to gain access to the drain hoses See: Interior Moulding / Trim/Headliner/Service and Repair/Headliner Removal. 2. Disconnect the front hoses (2) from the sunroof assembly (1). 3. Release the support clips (3) and disconnect the lower grommet and remove the hose. 4. Disconnect the rear hoses (2) from the sunroof assembly (1) and release the support clips (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Tube - Removal > Page 7110 5. Separate the remaining support clips (1). 6. Disconnect the grommet (2) from the body (3) and remove the rear hoses as necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Tube - Removal > Page 7111 Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Tube - Installation INSTALLATION 1. Install the rear hoses (4) and connect the grommets (2) to the body (3). 2. Connect the support clips (1). 3. Route the hose as required and connect the remaining support clips (3). 4. Connect the hoses (2) to the sunroof assembly (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Tube - Removal > Page 7112 5. Connect the front hose lower grommet to the body. 6. Connect the front hose (2) to the sunroof assembly (1) and connect the support clips (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments Sunroof / Moonroof Panel: Adjustments GLASS PANEL 1. Move the sunshade rearward to the open position. 2. Move the sunroof glass panel to the fully closed position. 3. Adjust the glass one corner at a time. a. Loosen four glass screws (1). b. Lift glass assembly and align the top of the glass panel to the top of the roof panel. c. Tighten screw to 3 Nm (26 in. lbs.). d. Repeat steps a. and b. for each corner of the glass panel. e. When properly adjusted, the front of the glass panel is 1.0 mm (0.04 in.) to 2.0 mm (0.08 in.) lower than the roof surface and the rear edge of the glass panel is 1.0 mm (0.04 in.) to 2.0 mm (0.08 in.) higher than the roof surface. NOTE: When properly adjusted, the front of the glass panel (3) is 1.0 mm (0.04 in.) to 2.0 mm (0.08 in.) lower than the roof surface (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Page 7116 NOTE: When properly adjusted, the rear edge of the glass panel (3) is 1.0 mm (0.04 in.) to 2.0 mm (0.08 in.) higher than the roof surface (2). 4. Verify sunroof operation and alignment. Check fit and re-adjust as necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Sunroof Glass - Removal Sunroof / Moonroof Panel: Service and Repair Sunroof Glass - Removal REMOVAL 1. Slide sunshade rearward to the open position. 2. Move the glass panel to the closed position. 3. Remove the four glass panel screws (1). 4. Lift off glass panel and remove from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Sunroof Glass - Removal > Page 7119 Sunroof / Moonroof Panel: Service and Repair Sunroof Glass - Installation INSTALLATION 1. Position glass panel (2) on to mechanism lift arm. 2. Start the four attaching screws (1). 3. Center glass in opening by running a business card around the glass. 4. Adjust glass panel See: Adjustments. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Glass Seal - Removal Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Glass Seal - Removal REMOVAL 1. Remove sunroof glass panel See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass Removal. 2. Place glass panel on clean work area with the top side up. Support the glass assembly from underside to avoid bending or otherwise damaging the mounting tabs. 3. Grasp the seal (1) and pull seal away from the glass panel (2). The seal is a one piece seal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Glass Seal - Removal > Page 7124 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Glass Seal - Installation INSTALLATION NOTE: Always position seal seam on center of the passenger side of glass panel. 1. Place seal (1) into position. 2. Seat the seal into the glass channel fully. Using care working the seal around the glass (2), being careful not to over stretch the seal while installing. 3. Install the glass panel See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Description and Operation Seat Back: Description and Operation DESCRIPTION REAR SEAT BACK - W/O RECLINER OPTION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Description and Operation > Page 7129 REAR SEAT BACK - RECLINER Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement Seat Back: Removal and Replacement Front REMOVAL Driver Seat 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions 2. Remove the seat cushionSee: Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 3. Remove both of the inner side shields (2). 4. Remove the lift lever trim cap (2). 5. Remove the screws (2) and remove the lift lever (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7132 6. Separate the clip (2). 7. Remove the recliner handle (1). 8. Remove the screws (2) attaching the inboard and outboard side shields (1) to the seat frame. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7133 9. Separate the clip fasteners (2) and remove the side shields from the seat cushion frame tabs (1). WARNING: Discard and replace the seat back bolts (1) with new bolts when servicing. Installing used bolts may result in the loosening of the seat back bolts after repair. Failure to follow these instructions may result in serious or fatal injury. 10. Remove and discard the bolts (1) and remove the seat back assembly (2). Passenger Seat 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions 2. Remove the seat cushionSee: Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 3. Fold the seat back (1) into the down position. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7134 4. Remove both of the inner side shields (1). 5. Release the cable housing (2) from the seat back frame and disconnect the recliner cable ends (4). 6. Remove the screw (5) and remove the recliner shields (1). 7. Remove the screw (3) attaching the inboard and outboard side shields to the seat frame. 8. Separate the clip fasteners (2) and remove the side shields from the seat cushion frame tabs (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7135 WARNING: Discard and replace the seat back bolts (2) with new bolts when servicing. Installing used bolts may result in the loosening of the seat back bolts after repair. Failure to follow these instructions may result in serious or fatal injury. 9. Remove and discard the bolts (2) and remove the seat back assembly (1). Rear REMOVAL 1. Remove the seat cushion See: Seat Cover/Service and Repair/Seat Cushion Cover - Removal 2. Remove the belt buckle bolt (2) and the buckle (1). 3. Remove the floor bracket or recliner bolts (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7136 4. Fold the seats forward. 5. Remove the nut (5) and bolts (6) and remove the 40% seat back (4). 6. Remove the nuts from the studs (2) and remove the 60% seat back. Front INSTALLATION Driver Seat 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions WARNING: Discard and replace the seat back bolts (1) with new bolts when servicing. Installing used bolts may result in the loosening of the seat back bolts after repair. Failure to follow these instructions may result in serious or fatal injury. 2. Install the seat back assembly (2) and install the new bolts (1). 3. Tighten the bolts to 40 Nm (30 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7137 4. Position the side shields onto the seat adjuster tabs (1) and seat the clip (2) fully. 5. Install the outer side shield screw (2). 6. Install the clip (2) onto the recliner handle, if necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7138 7. Position the recliner handle (1) onto the spined shaft (2) and seat fully. 8. Install the height adjuster handle (1) and install the screws (2), if equipped. 9. Position the lift lever trim cap (2) and seat fully. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7139 10. Position the inner side shields (2) and seat fully. 11. Install the seat cushion, See: Seat Cover/Service and Repair/Seat Cushion Cover - Installation. Passenger Seat WARNING: Discard and replace the seat back bolts (2) with new bolts when servicing. Installing used bolts may result in the loosening of the seat back bolts after repair. Failure to follow these instructions may result in serious or fatal injury. 1. Install the seat back assembly (1) and install the new bolts (2). 2. Tighten the bolts to 40 Nm (30 ft. lbs.). 3. Position the side shields onto the seat adjuster tabs (1) and seat the clip (2) fully. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7140 4. Install the screws (3) attaching the inboard and outboard side shields to the seat frame. 5. Install the recliner shields (1) and install the screws (5). 6. Connect the recliner cable ends (4) and fasten the cable housing (2) to the seat back frame. 7. Install both of the inner side shields (1). 8. Position the seat back (1) into the upright position. 9. Install the seat cushion, See: Seat Cover/Service and Repair/Seat Cushion Cover - Installation Rear INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7141 1. Install the 60% seat section (1) over the studs (2) and install the nuts (3). 2. Install the 40% seat section (4) over the stud and seat bracket and install the seat bracket bolts (6). 3. Tighten the seat bracket bolts (6) to 46 Nm (34 ft. lbs.). 4. Install the nut (5). 5. Tighten the nuts (5 and 3) to 80 Nm (60 ft. lbs.). 6. Position the seat backs (3) up and latch. 7. Install the belt buckles (1) and install the bolt (2). 8. Tighten the buckle bolt to 66 Nm (49 ft. lbs.) 9. Install the bolts (4) and tighten to 80 Nm (59 ft. lbs.) 10. Install the seat cushion See: Seat Cover/Service and Repair/Seat Cushion Cover - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7142 Seat Back: Overhaul Front DISASSEMBLY 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions 2. Remove the seat back See: Removal and Replacement/Seat Back Removal. 3. Remove the headrest. 4. Remove the lumbar handle, if equipped. 5. Remove the back panel (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7143 6. Separate the J-straps (1) and the push-pin fasteners (2). 7. Release the push-pin fasteners (1) and release the cover from the hooks (2). 8. Separate the seat cover (3) from the foam cushion (1) and cut off all hog rings (2) attaching cover to the foam. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7144 9. Squeeze the locking tab (3) and remove the headrest sleeves (1) and remove the cover. 10. Remove the seat back cover and cushion. 11. Remove the lumbar adjuster screws (1). 12. Disconnect the lumbar cable (2) and separate the cable housing (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7145 13. Release the lumbar mat side wires (1) by pulling out on the wire supports and then pulling them in. 14. Squeeze the lower support wires (1) in and release the lower wires. 15. Pull the upper support wires (1) down and release the lumbar mat from the seat back frame. 16. Seat mechanical part description and specifications are found in the seat description. See: Description and Operation Rear DISASSEMBLY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7146 1. Remove the screws (1) and remove the latch bezel (2). 2. Remove the bolts (2) and remove the latch (1). 3. Remove the screws (1) and remove the tether trim bezels (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7147 4. Remove the headrest. 5. Separate the zip strips (1 and 2). 6. Remove the push pin fasteners (3). 7. Separate the inner cover (2) from the hooks (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7148 8. Unzip the cover (1). 9. Remove the foam insert (2) from the seat back assembly (1). 10. Separate the seat cover (3) from the foam cushion (1) and cut off all hog rings (2) attaching the cover to the foam. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7149 11. Squeeze the locking tab (3) and remove the headrest sleeves (1). 12. Remove the seat back cover and cushion. Front ASSEMBLY 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions 2. Place lumbar mat onto seat back frame and insert the upper support wires (1) into the frame. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7150 3. Squeeze the lower support wires (1) together and insert into the lower frame. 4. Squeeze the side support wires together and insert them into the sides of the seat back frame. 5. Connect the lumbar cable housing (1) and connect the cable end (2) to the anchor. 6. Install the lumbar adjuster and install the adjuster screws (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7151 7. Position the seat back cushion on the frame and position the cover over the cushion. 8. Attach the seat cover (3) to the seat back cushion (1) and install new hog rings (2) as required. 9. Install the push pins (1) and connect the inner cover to the hooks (2). 10. Install the push-pin fasteners (2) and connect the J-straps (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7152 11. Install the headrest sleeves (2). 12. Position the seat back panel (1) onto the seat back (2) and seat fully. 13. Press the headrest sleeve release buttons and install the headrest. 14. Install the seat back See: Removal and Replacement/Seat Back - Installation. Rear ASSEMBLY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7153 1. Position the seat back cushion on the frame and position the cover over the cushion. 2. Attach the seat cover (3) to the seat back cushion (1) and install new hog rings (2) as required. 3. Position the foam insert (2) back at the base of the seat back assembly (1). 4. Zip the cover back over the frame. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7154 5. Install the push pin fasteners (3). 6. Position the inner cover (2) over the frame hooks (1). 7. Fasten the upper (1) and lower (2) zip strips at the bottom of the seat back. 8. Install the child tether bezels (2) and install the screws (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7155 9. Install the latch (1) and install the bolts (2). 10. Tighten the bolts to 28 Nm (21 ft. lbs.). 11. Install the latch bezel (2) and install the screws (1). 12. Install the headrest sleeves (2), if equipped. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7156 13. Press the headrest sleeve release buttons and install the headrest, if equipped. 14. Install the seat back See: Removal and Replacement/Seat Back - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Cushion Cover - Removal Seat Cover: Service and Repair Seat Cushion Cover - Removal Front REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions 2. Move the seat to the forward position and disconnect and isolate the negative battery cable. 3. Remove the bolts (2) and the straps (1). 4. Disconnect the electrical connector, if equipped. 5. Lift the front of the seat cushion (2) up and slide out from under the seat back cushion (1). Rear REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Cushion Cover - Removal > Page 7161 1. Remove the bolts (2). 2. Lift the front of the cushion (3) up and remove the cushion from under the seat back. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Cushion Cover - Removal > Page 7162 Seat Cover: Service and Repair Seat Cushion Cover - Disassembly Front DISASSEMBLY 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions 2. Remove the seat cushion, See: Service and Repair/Seat - Removal. 3. Release the seat cushion cover J-straps (2) from the seat pan and remove the cushion from the pan. 4. Remove the hog rings (1) and separate the seat cushion cover (2) from the seat cushion foam (3). Rear DISASSEMBLY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Cushion Cover - Removal > Page 7163 1. Remove the seat cushion See: Service and Repair/Seat - Removal. 2. Separate the J-straps (1) from the seat frame. 3. Remove the hog rings (2) connecting the seat cover (3) to the seat cushion foam (1) and separate from the seat cushion frame. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Cushion Cover - Removal > Page 7164 Seat Cover: Service and Repair Seat Cushion Cover - Assembly Front ASSEMBLY 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions 2. Position the seat cushion cover (2) over the seat cushion foam (3) and attach new hog rings (1). 3. Connect the seat cushion cover J-straps (2) to the seat pan. Rear ASSEMBLY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Cushion Cover - Removal > Page 7165 1. Place the cushion cover (3) onto the cushion foam (1) and install new hog rings (2). 2. Connect the J-straps (1) to the seat cushion frame. 3. Install the seat cushion See: Service and Repair/Seat - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Cushion Cover - Removal > Page 7166 Seat Cover: Service and Repair Seat Cushion Cover - Installation Front INSTALLATION 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions 2. Position the rear of the seat cushion assembly (2) back under the seat back (1) and position the front of the cushion down over the seat adjuster frame. 3. Install the seat cushion bushings and straps (1) and install the bolts (2). 4. Tighten the bolts to 11 Nm (8 ft. lbs.). Rear INSTALLATION Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Cushion Cover - Removal > Page 7167 1. Place the seat cushion into the vehicle and tuck the rear of the cushion (1) up under the seat belt buckles and rear seat back. 2. Lower the front of the cushion (3) down and install the bolts (2). 3. Tighten the bolts to 80 Nm (60 ft. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations Seat Heater: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Page 7171 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Left Seat Back Heater (Component Side) (Left Seat Back Pigtail) 2 Way Seat Heater: Diagrams Left Seat Back Heater (Component Side) (Left Seat Back Pigtail) 2 Way Connector (COMPONENT SIDE) - (LEFT SEAT BACK PIGTAIL) 2 WAY HEATER-SEAT BACK-LEFT (COMPONENT SIDE) - (LEFT SEAT BACK PIGTAIL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Left Seat Back Heater (Component Side) (Left Seat Back Pigtail) 2 Way > Page 7174 Seat Heater: Diagrams Left Seat Cushion Heater C1 (Component Side) (Left Seat Cushion Pigtail) 2 Way Connector C1 (COMPONENT SIDE) - (LEFT SEAT CUSHION PIGTAIL) 2 WAY HEATER-SEAT CUSHION-LEFT (COMPONENT SIDE) - (LEFT SEAT CUSHION PIGTAIL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Left Seat Back Heater (Component Side) (Left Seat Back Pigtail) 2 Way > Page 7175 Seat Heater: Diagrams Left Seat Cushion Heater C1 (Left Seat) 2 Way Connector C1 - (LEFT SEAT) 2 WAY HEATER-SEAT CUSHION-LEFT - (LEFT SEAT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Left Seat Back Heater (Component Side) (Left Seat Back Pigtail) 2 Way > Page 7176 Seat Heater: Diagrams Left Seat Cushion Heater C2 (Component Side) (Left Seat Cushion Pigtail) 2 Way Connector C2 (COMPONENT SIDE) - (LEFT SEAT CUSHION PIGTAIL) 2 WAY HEATER-SEAT CUSHION-LEFT (COMPONENT SIDE) - (LEFT SEAT CUSHION PIGTAIL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Left Seat Back Heater (Component Side) (Left Seat Back Pigtail) 2 Way > Page 7177 Seat Heater: Diagrams Left Seat Back Heater (Component Side) (Left Seat Back Pigtail) 2 Way Connector (COMPONENT SIDE) - (LEFT SEAT BACK PIGTAIL) 2 WAY HEATER-SEAT BACK-LEFT (COMPONENT SIDE) - (LEFT SEAT BACK PIGTAIL) 2 WAY Left Seat Cushion Heater C1 (Component Side) (Left Seat Cushion Pigtail) 2 Way Connector C1 (COMPONENT SIDE) - (LEFT SEAT CUSHION PIGTAIL) 2 WAY HEATER-SEAT CUSHION-LEFT (COMPONENT SIDE) - (LEFT SEAT CUSHION PIGTAIL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Left Seat Back Heater (Component Side) (Left Seat Back Pigtail) 2 Way > Page 7178 Left Seat Cushion Heater C1 (Left Seat) 2 Way Connector C1 - (LEFT SEAT) 2 WAY HEATER-SEAT CUSHION-LEFT - (LEFT SEAT) 2 WAY Left Seat Cushion Heater C2 (Component Side) (Left Seat Cushion Pigtail) 2 Way Connector C2 (COMPONENT SIDE) - (LEFT SEAT CUSHION PIGTAIL) 2 WAY HEATER-SEAT CUSHION-LEFT (COMPONENT SIDE) - (LEFT SEAT CUSHION PIGTAIL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Left Seat Back Heater (Component Side) (Left Seat Back Pigtail) 2 Way > Page 7179 Right Seat Back Heater (Component Side) (Right Seat Back Pigtail) 2 Way Connector (COMPONENT SIDE) - (RIGHT SEAT BACK PIGTAIL) 2 WAY HEATER-SEAT BACK-RIGHT (COMPONENT SIDE) - (RIGHT SEAT BACK PIGTAIL) 2 WAY Right Seat Cushion Heater C1 (Component Side) (Right Seat Cushion Pigtail) 2 Way Connector C1 (COMPONENT SIDE) - (RIGHT SEAT CUSHION PIGTAIL) 2 WAY HEATER-SEAT CUSHION-RIGHT (COMPONENT SIDE) - (RIGHT SEAT CUSHION PIGTAIL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Left Seat Back Heater (Component Side) (Left Seat Back Pigtail) 2 Way > Page 7180 Right Seat Cushion Heater C1 (Right Seat) 2 Way Connector C1 - (RIGHT SEAT) 2 WAY HEATER-SEAT CUSHION-RIGHT - (RIGHT SEAT) 2 WAY Right Seat Cushion Heater C2 (Component Side) (Right Seat Cushion Pigtail) 2 Way Connector C2 (COMPONENT SIDE) - (RIGHT SEAT CUSHION PIGTAIL) 2 WAY HEATER-SEAT CUSHION-RIGHT (COMPONENT SIDE) - (RIGHT SEAT CUSHION PIGTAIL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Left Seat Back Heater (Component Side) (Left Seat Back Pigtail) 2 Way > Page 7181 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats - Description Seat Heater: Description and Operation Heated Seats - Description DESCRIPTION WARNING: The front passenger seat assembly contains critical components that affect the front passenger airbag deployment. Correctly functioning front passenger seat components are critical for the Occupant Classification System (OCS) to properly classify the front passenger and calculate the proper airbag deployment. Unapproved modifications or service procedures to the front passenger seat assembly, its related components, or trim cover may inadvertently change the airbag deployment in case of a frontal crash. This could result in death or serious injury to the front seat passenger if the vehicle is involved in an accident. The following requirements must be strictly adhered to: Do not modify the front passenger seat assembly or components in any way. - Do not modify the front seat center console or center position seat in any way. - Do not use prior or future model year seat trim covers not designated for the specific model being repaired. Always use the correct seat trim cover specified for the vehicle. - Do not replace the seat trim cover with an aftermarket trim cover. - Do not add a secondary trim cover other than those approved by Chrysler/Mopar(R). - At no time should any Supplemental Restraint System (SRS) component or SRS related component or fastener be modified or replaced with any part except those which are approved by Chrysler/Mopar(R). Vehicles with the heated seat option can be visually identified by the two heated seat switches located in the center stack (1) of the instrument panel. The switches are located on the outer edges of the accessory switch bank (2). The heated seat system allows the driver and front seat passenger to select from two different levels of electrical seat heating (HI/LO). The heated seat system for this vehicle includes the following major components, which are described in further detail later: - Heated Seat Elements - Four heated seat elements are used per vehicle. Two heated seat elements are integral to each seat, one in the seat back and the other in the seat cushion. - Heated Seat Module - One heated seat module is used per vehicle. The Heated Seat Module is mounted under the left front seat. This module contains the control logic and software for the front heated seat system. The module communicates on the Local Interface Network (LIN) data bus. - Heated Seat Switches - Two heated seat switches are used per vehicle, one for each heated seat. Both switches are mounted in the instrument panel center stack. - Instrument Cluster (CCN) - A Cab Compartment Node (CCN) is part of the instrument cluster on this vehicle. The CCN utilizes integrated software and information carried on the LIN data bus. The CCN serves as the link between the heated seat switches and the heated seat module. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats - Description > Page 7184 Seat Heater: Description and Operation Heated Seats - Operation OPERATION The heated seat system operates on battery current received through a fuse in the Totally Integrated Power Module (TIPM). Fused ignition switch output (Run) circuits are used, so that the heated seat system will only operate when the ignition switch is in the ON position. The heated seat system will turn Off automatically whenever the ignition switch is turned to any position except ON. A Heated Seat Module is used to control the heated seat system. The module responds to heated seat switch messages and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switches are depressed a switch status message is sent to the Cab Compartment Node (CCN) or instrument cluster via the Local Interface Network (LIN) data bus. The CCN then sends a message via the LIN data bus to the heated seat module, signaling the module to energize the heating element for the selected seat. Amber Light Emitting Diodes (LEDs) in the top portion of each switch indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. The heated seat module sends the LED illumination message to the CCN via the LIN data bus. The CCN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. The heated seat module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated once per ignition cycle. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after thirty minutes (twenty six minutes on first activation of an ignition cycle) of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting also turns off automatically after thirty minutes. The module will automatically turn off the heating elements if it detects an OPEN or LOW short in the heating element circuit. In the event an OPEN or LOW short in the heating element circuit is detected when the heated seats are first initialized, the two LEDs will light for two seconds and go out as an indicator of a system problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats - Description > Page 7185 Seat Heater: Description and Operation Heater Pad - Description DESCRIPTION Vehicles equipped with the optional heated seat system have two, carbon fiber heated seat elements, located in each front seat. One heating element is used for each seat cushion and another for each seat back. Each of the heated seat element consists of multiple heating circuits operating in parallel throughout the carbon fiber element. The heated seat elements are captured between the leather or cloth trim cover and the seat cushion assembly. If a malfunction occurs in one or more of the individual carbon fiber circuits, the others will continue to provide heat. The heated seat elements cannot be repaired. If found to be damaged or inoperative, a new heating element assembly must be installed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats - Description > Page 7186 Seat Heater: Description and Operation Heater Pad - Operation OPERATION One end of the heated seat element is connected to ground at all times through a splice under the seat. Battery current is directed to the other end of the heated seat element by the heated seat module. The heated seat module will energize the heated seat element when the heated seat switch is depressed in the LOW or HIGH position. As electrical current passes through the heated seat element, the resistance of the wire used in the element disperses some of the electrical current in the form of heat. The heat produced by the heated seat element then radiates through the underside of the seat cushion and seat back trim covers, warming the seat cover and its occupant. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat System Seat Heater: Testing and Inspection Heated Seat System HEATED SEAT SYSTEM In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat System > Page 7189 Seat Heater: Testing and Inspection Heater Pad HEATED SEAT ELEMENT Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. The wire harness connectors (2 AND 3) for the heating elements are located under the seat (1). NOTE: When checking heated seat elements for continuity, be certain to move the heating element being checked. Moving the element, such as sitting in the seat will eliminate the possibility of an intermittent open in the element which would only be evident if the element was in a certain position. Failure to check the element in various positions could result in an incomplete test. 1. Locate and disconnect the seat electrical connector. 2. Check the resistance between the circuit leading in and out of the suspect heated seat element. The resistance should be between 3.0 - 5.5 ohms for a seat cushion element and 4.0 - 6.0 ohms for a seat back element. If OK, See: Heated Seat System. If not OK, replace the inoperative heated seat element. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Heater Pad - Removal Seat Heater: Service and Repair Heater Pad - Removal REMOVAL NOTE: The factory installed heating element can be removed from the foam cushions by carefully peeling the element off along the adhesive lines. 1. Disconnect and isolate the battery negative cable. 2. Remove the appropriate seat cushion, See: Seat Cover/Service and Repair/Seat Cushion Cover - Removal or seat back trim cover. 3. Disconnect the inoperative heated seat cushion or seat back element electrical connectors (2). 4. Remove the heating element by peeling it away from the foam, being careful not to remove excessive foam in the process. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Heater Pad - Removal > Page 7192 Seat Heater: Service and Repair Heater Pad - Installation INSTALLATION CAUTION: During the installation of the replacement heating element, be careful not to fold or crease the element assembly. Folds or creases will cause premature failure. NOTE: The factory installed heating element should be completely removed from the system and discarded. 1. Peel off the adhesive backing on the back of the replacement heating element (2) and stick directly on where the factory installed heating element (1 was). 2. Connect the new heating element electrical connectors (3 AND 4). 3. Connect the battery negative cable. 4. Verify heated seat system operation. 5. Install the appropriate seat cushion, See: Seat Cover/Service and Repair/Seat Cushion Cover - Installation or seat back trim cover. NOTE: Make certain the seat wire harness is correctly routed through the seat and seat back. The excess wire between the cushion and back elements should be securely tucked between the rear of the cushion foam and the rear carpet flap of the trim cover. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Page 7196 Seat Heater Control Module: Diagrams Connector - (DRIVER SEAT) 10 WAY MODULE-HEATED SEATS - (DRIVER SEAT) 10 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description Seat Heater Control Module: Description and Operation Heated Seat Module - Description DESCRIPTION The heated seat module (2) is located under the left front seat. It has a single electrical connector (1) and a push pin style retainer that secures it to the seat pan. The module can be accessed from under the front left seat with the seat in the full back position. The heated seat module is a microprocessor designed to use the Local Interface Network (LIN) data bus messages from the instrument cluster also known as the Cabin Compartment Node (CCN). The CCN receives inputs from the heated seat switches and in turn signals the heated seat module to operate the heated seat elements for both front seats. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description > Page 7199 Seat Heater Control Module: Description and Operation Heated Seat Module - Operation OPERATION The heated seat module operates on fused battery current received from the ignition switch. The module is grounded to the body at all times through the electrical connector. Inputs to the module include Local Interface Network (LIN) data bus messages and standard hardwired 12 volt power and ground. In response to the LIN inputs the heated seat module will control the battery current to the appropriate heated seat elements. When a heated seat switch LIN data bus signal is received by the heated seat module, the module energizes the selected heated seat element. The Low heat set point is about 38° C (100.4° F), and the High heat set point is about 42° C (107.6° F). In addition to operating the heated seat elements, the heated seat module sends LED illumination messages to the CCN via the LIN data bus. The CCN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. If the heated seat module detects a heated seat element OPEN or SHORT circuit, it will record and store the appropriate diagnostic trouble code (DTC). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Page 7200 Seat Heater Control Module: Testing and Inspection HEATED SEAT MODULE In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal Seat Heater Control Module: Service and Repair Heated Seat Module - Removal REMOVAL CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Position the left front seat to the full rearward position. 2. Disconnect and isolate the battery negative cable. 3. Disconnect the wire harness connector (4) from the heated seat module (3). 4. Unsnap the heated seat module retaining tab (2) from the seat pan (1). 5. Remove the heated seat module (3) from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal > Page 7203 Seat Heater Control Module: Service and Repair Heated Seat Module - Installation INSTALLATION CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and installation. Use care to properly align tab to prevent binding that could result in tab breakage. 1. Install the heated seat module (3) into the vehicle. 2. Position the retaining tab (2) with the mounting hole in the seat pan (1). Firmly apply even pressure to the module (3) until the mounting tab is fully seated. 3. Connect the wire harness connector (4) to the heated seat module (3). 4. Connect the battery negative cable. 5. Check for proper heated seat system operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description Seat Heater Switch: Description and Operation Heated Seat Switch - Description DESCRIPTION The heated seat switches are located in the center stack (1) of the instrument panel. The switches are located on the outer edges of the accessory switch bank (2). If either of the switches is damaged or inoperative the complete accessory switch bank assembly must be replaced. When either of the heated seat switches are depressed a switch status message is sent to the Cab Compartment Node (CCN) or instrument cluster via the Local Interface Network (LIN) data bus. The CCN then sends a message via the LIN data bus to the heated seat module, signaling the module to energize the heating element for the selected seat. Amber Light Emitting Diodes (LEDs) in the top portion of each switch indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. The heated seat module sends the LED illumination message to the CNN via the LIN data bus. The CNN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. The LED indicator lamps in each heated seat switch cannot be repaired. If the LED lamps are inoperative or damaged, or the switch is inoperative or damaged the complete accessory switch bank assembly must be replaced. For Service information See: Accessories and Optional Equipment/Integrated Accessory Switch Assembly/Service and Repair/Instrument Cluster Switch Pod - Removal orSee: Accessories and Optional Equipment/Integrated Accessory Switch Assembly/Service and Repair/Instrument Cluster Switch Pod - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description > Page 7208 Seat Heater Switch: Description and Operation Heated Seat Switch - Operation OPERATION The heated seat switches are active any time the Local Interface Network (LIN) data bus is active. Depressing the heated seat switch provides a switch status message to the Cabin Compartment Node (CCN) via the LIN data bus. The CCN is responsible for supplying the LIN data bus message to the heated seat module, signaling the module to power the heated seat element of the selected seat and maintain the temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the CCN will go through the process again to change the temperature setting. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Page 7209 Seat Heater Switch: Testing and Inspection HEATED SEAT SWITCH In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal Seat Heater Switch: Service and Repair Heated Seat Switch - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The heated seat switches are integral to the accessory switch bezel and cannot be serviced separately. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a work bench See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the screws that secure the accessory switch bank (4) to the back of the center bezel and remove the accessory switch bank. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal > Page 7212 Seat Heater Switch: Service and Repair Heated Seat Switch - Installation INSTALLATION NOTE: There are different instrument panel accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. 1. Position the accessory switch bank (4) onto the back of the instrument panel center bezel. 2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 1 Nm (8 in. lbs.). 3. Install the center bezel onto the instrument panel See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Reconnect the negative battery cable. 5. Verify heated seat system operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection Power Door Lock Switch: Testing and Inspection DOOR LOCK SWITCH 1. Remove the switch. 2. Using an ohmmeter, refer to Door Lock Switch Test table to determine if switch resistance is correct in the Lock and Unlock switch positions. Refer to Wiring Diagrams for harness connector pin-outs. DOOR LOCK SWITCH TEST Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal Power Door Lock Switch: Service and Repair Power Lock Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Removal. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal > Page 7223 Power Door Lock Switch: Service and Repair Power Lock Switch - Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Installation 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7227 Power Mirror Switch: Diagrams Connector (LHD) - (LEFT FRONT DOOR) 10 WAY SWITCH-MIRROR (LHD) - (LEFT FRONT DOOR) 10 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7228 Power Mirror Switch: Testing and Inspection POWER MIRROR SWITCH - LHD 1. Disconnect and isolate the battery negative cable. 2. Remove power mirror switch See: Service and Repair/Power Mirror Switch - Removal. 3. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Test table. 4. If test results are not obtained as shown in the Mirror Switch Test table, replace the switch. MIRROR SWITCH TEST TABLE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7229 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch - Removal Power Mirror Switch: Service and Repair Power Mirror Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Removal. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch - Removal > Page 7232 Power Mirror Switch: Service and Repair Power Mirror Switch - Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Installation 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description Seat Heater Switch: Description and Operation Heated Seat Switch - Description DESCRIPTION The heated seat switches are located in the center stack (1) of the instrument panel. The switches are located on the outer edges of the accessory switch bank (2). If either of the switches is damaged or inoperative the complete accessory switch bank assembly must be replaced. When either of the heated seat switches are depressed a switch status message is sent to the Cab Compartment Node (CCN) or instrument cluster via the Local Interface Network (LIN) data bus. The CCN then sends a message via the LIN data bus to the heated seat module, signaling the module to energize the heating element for the selected seat. Amber Light Emitting Diodes (LEDs) in the top portion of each switch indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. The heated seat module sends the LED illumination message to the CNN via the LIN data bus. The CNN then sends the LED illumination message to the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a third time will shut the heating elements off. The LED indicator lamps in each heated seat switch cannot be repaired. If the LED lamps are inoperative or damaged, or the switch is inoperative or damaged the complete accessory switch bank assembly must be replaced. For Service information See: Accessories and Optional Equipment/Integrated Accessory Switch Assembly/Service and Repair/Instrument Cluster Switch Pod - Removal orSee: Accessories and Optional Equipment/Integrated Accessory Switch Assembly/Service and Repair/Instrument Cluster Switch Pod - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description > Page 7237 Seat Heater Switch: Description and Operation Heated Seat Switch - Operation OPERATION The heated seat switches are active any time the Local Interface Network (LIN) data bus is active. Depressing the heated seat switch provides a switch status message to the Cabin Compartment Node (CCN) via the LIN data bus. The CCN is responsible for supplying the LIN data bus message to the heated seat module, signaling the module to power the heated seat element of the selected seat and maintain the temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the CCN will go through the process again to change the temperature setting. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 7238 Seat Heater Switch: Testing and Inspection HEATED SEAT SWITCH In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN) data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above 15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat system appears inoperative. Before any testing of the heated seat system is attempted, the battery should be fully-charged. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal Seat Heater Switch: Service and Repair Heated Seat Switch - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The heated seat switches are integral to the accessory switch bezel and cannot be serviced separately. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a work bench See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the screws that secure the accessory switch bank (4) to the back of the center bezel and remove the accessory switch bank. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal > Page 7241 Seat Heater Switch: Service and Repair Heated Seat Switch - Installation INSTALLATION NOTE: There are different instrument panel accessory switch banks available based on the option content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle options. 1. Position the accessory switch bank (4) onto the back of the instrument panel center bezel. 2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 1 Nm (8 in. lbs.). 3. Install the center bezel onto the instrument panel See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Reconnect the negative battery cable. 5. Verify heated seat system operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Sunroof Switch - Description Sunroof / Moonroof Switch: Description and Operation Sunroof Switch - Description DESCRIPTION The power sunroof switch (2) is a combination push-button and rocker switch module mounted in the Courtesy/Reading Lamp assembly (1). The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof express open (back of switch pushed and released) - Power sunroof closed (front of switch pushed) - Power sunroof express closed (front of switch pushed and released) - Power sunroof vent (switch center button pushed) The power sunroof switch cannot be repaired. If the individual components are damaged or inoperative the switch assembly must be replaced, See: Service and Repair/Sunroof Switch Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Sunroof Switch - Description > Page 7246 Sunroof / Moonroof Switch: Description and Operation Sunroof Switch - Operation OPERATION The sunroof is electrically operated from two switches located in the headliner on the courtesy/reading lamp assembly. The power sunroof switch is hard wired to the sunroof motor/module assembly. The "VENT" switch is a push button type switch and opens the sunroof to the vent position only. The other switch "OPEN/CLOSED" is a rocker type switch for opening and closing the sunroof. Pressing and releasing the open button once, the sunroof will express open and the wind deflector will raise. If the button is pressed a second time the sunroof will stop in that position. Pressing and releasing the close button once will express close the sunroof. If the close button is pressed a second time during the express close operation the sunroof will stop in that position. The switch is grounded at one terminal and receives a 5 volt signal from the sunroof motor/module on the remaining three terminals. The switch pulls down the 5 volt reference voltage from the module signaling it to perform the desired function. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Description and Operation > Page 7247 Sunroof / Moonroof Switch: Testing and Inspection SUNROOF SWITCH For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the power sunroof switch, See: Service and Repair/Sunroof Switch - Removal. 2. Disconnect the power sunroof switch wire harness connector. 3. With the ignition key in the "RUN" position check for 5 volts on the "OPEN", "CLOSE" and "VENT" circuits of the sunroof switch harness connector. If OK, go to 4. If not OK, inspect the wiring harness and connectors between the motor/module and switch for damage and repair as necessary. 4. With the ignition key in the "OFF" position check for continuity between the ground circuit of the sunroof switch harness connector and a known good ground. Continuity should be present. If OK, go to 5. If not OK, inspect the wiring harness and connector and repair the ground circuit as necessary. 5. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage and repair as necessary. If not OK, replace the power sunroof switch, See: Service and Repair/Sunroof Switch Removal. POWER SUNROOF SWITCH CONTINUITY TABLE Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch - Removal Sunroof / Moonroof Switch: Service and Repair Sunroof Switch - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the courtesy/reading lamp lens (5). Insert a suitable flat bladed tool into the slot (6) in the courtesy/reading lamp assembly (2). Pivot the lens down and to the left to release the holding tab (4). 3. Using a suitable flat bladed tool, release the mounting tabs (5) from the sides of the sunroof control switch (4) and pull the switch down from the courtesy/reading lamp assembly (2). 4. Disconnect the electrical connector (3) from the sunroof control switch (4). 5. Remove the switch from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch - Removal > Page 7250 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch - Installation INSTALLATION 1. Position the sunroof control switch (4) into the vehicle. 2. Connect the sunroof control switch electrical connector (3). 3. Insert the sunroof control switch (4) into the courtesy/reading lamp assembly (2). Push up on the switch until it is securely held in place by the mounting tabs (5). 4. Insert the mounting tab (4) on the lamp lens (5) into the right side of the lamp assembly and pivot the lens up until it snaps securely in place. 5. Connect the negative battery cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations Sound Proofing / Insulation: Locations SOUND DEADENER LOCATIONS Preferred Mopar Products: - Expandable Foam - Part No. 05142864AA - Dispenser - Part No. 05016570AA Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 7254 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 7255 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 7256 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 7257 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 7258 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 7259 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Service and Repair > Upper Closure Panel - Removal Air Dam: Service and Repair Upper Closure Panel - Removal REMOVAL 1. Rotate the two retaining clips (3) and remove the air cleaner snorkel (2) from air cleaner box (1). 2. Remove fascia fasteners (1). 3. Remove closure panel fasteners (2). 4. Remove closure panel from vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Service and Repair > Upper Closure Panel - Removal > Page 7265 Air Dam: Service and Repair Upper Closure Panel - Installation INSTALLATION 1. Slide closure panel under fascia aligning holes. 2. Tighten fascia fasteners (1). 3. Insert closure panel fasteners (2) and tighten. 4. Insert air cleaner snorkel into air box opening. Rotate the two retaining clips (3) and fasten into closure panel ensuring fit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Spoiler - Removal Spoiler: Service and Repair Spoiler - Removal REMOVAL NON SRT 4 1. Open liftgate. 2. Remove liftgate upper molding . 3. Remove 5 body plugs. 4. Remove four nuts (3) on spoiler studs. 5. Disengage center push pin. 6. If equipped, remove satellite wire (2) connector (1). 7. Disconnect CHMSL wire. 8. Remove spoiler (5) from vehicle (4). SRT 4 1. Open liftgate. 2. Remove liftgate upper molding . 3. Remove the body plugs. 4. Remove the nuts (1) from the spoiler studs. 5. Disconnect the electrical connector (2) from the center high mount stop lamp. 6. If equipped, remove satellite wire (2) connector (1). 7. Disconnect the washer hose (3) from the washer nozzle. 8. Remove spoiler (4) from the liftgate. 9. Clean adhesive residue with MOPAR(R) Super Clean solvent or equivalent. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Spoiler - Removal > Page 7270 Spoiler: Service and Repair Spoiler - Installation INSTALLATION NON SRT 4 1. If equipped, connect satellite wire (2) connector (1). 2. Replace seal if necessary. 3. Connect CHMSL wire. 4. Wipe ends of liftgate with alcohol to clean surface for foam spacers. 5. Remove tape liners from foam spacers on ends of spoiler. 6. Place spoiler (5) onto vehicle (4). 7. Press center push pin into center hole in liftgate. 8. Install four spoiler nuts (3) onto spoiler studs. 9. Install spoiler plugs. 10. Press spoiler above spacers to adhere tape to liftgate. 11. Install liftgate upper molding . SRT 4 1. If equipped, connect satellite wire (2) connector (1). 2. Connect the washer hose (3) to the washer nozzle. 3. Connect the electrical connector (2) to the center high mount stop lamp and make sure the harness is install to the clip on the spoiler. NOTE: Make sure the adhesive patch areas are completely clean prior to installation of the spoiler. Due not touch any part of the adhesive tape once the cover strips have been removed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Spoiler - Removal > Page 7271 4. Remove the adhesive cover strips, install spoiler (4) to the lift gate and press down on the areas of the spoiler that have the adhesive patches installed. 5. Install the four nuts (1) to the spoiler studs. 6. Install the body plugs. 7. Install the liftgate upper molding . Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Cover - Removal Cowl Moulding / Trim: Service and Repair Cowl Panel Cover - Removal REMOVAL 1. Remove the wiper arms (2), . See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 2. Remove the hood seal (4). 3. Remove the screws (3) and remove the panel (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Cover - Removal > Page 7278 Cowl Moulding / Trim: Service and Repair Cowl Panel Cover - Installation INSTALLATION 1. Position the end seals (1) into place. 2. Install the panel (2) and install the screws (3). 3. Install the hood seal (4). 4. Install the wiper arms (2), . See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Glass Seal - Removal Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Glass Seal - Removal REMOVAL 1. Remove sunroof glass panel See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass - Removal. 2. Place glass panel on clean work area with the top side up. Support the glass assembly from underside to avoid bending or otherwise damaging the mounting tabs. 3. Grasp the seal (1) and pull seal away from the glass panel (2). The seal is a one piece seal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Glass Seal - Removal > Page 7284 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Glass Seal - Installation INSTALLATION NOTE: Always position seal seam on center of the passenger side of glass panel. 1. Place seal (1) into position. 2. Seat the seal into the glass channel fully. Using care working the seal around the glass (2), being careful not to over stretch the seal while installing. 3. Install the glass panel See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7289 Cruise Control Switch: Diagrams Connector - (STEERING WHEEL) 3 WAY SWITCH-SPEED CONTROL - (STEERING WHEEL) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal Cruise Control Switch: Service and Repair Speed Control Switch - Removal REMOVAL WARNING: Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. This will disable the front airbag system. Failure to disconnect the battery could result in accidental front airbag module deployment and possible personal injury.Do not place a non-deployed airbag face down on a hard surface as the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. 1. Disconnect and isolate the negative battery cable before beginning steering wheel removal. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. 2. Turn off ignition. 3. Remove the driver's side airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Removal. 4. Disconnect electrical connector (1) from horn switch (2). 5. Remove mounting screws (3) and horn switch (2) from steering wheel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal > Page 7292 6. Disconnect electrical connector (1) from speed control switch (3). 7. Remove screws (4) from speed control switch (3). 8. Remove speed control switch (3) from steering wheel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal > Page 7293 Cruise Control Switch: Service and Repair Speed Control Switch - Installation INSTALLATION 1. Install speed control switch (3) onto the locating pin (2) in the steering wheel. Make sure rubber seal is in place around switch. 2. Install speed control switch mounting screws (4) and tighten screws to 1.6 Nm (15 ins. lbs.). 3. Connect electrical connector (1) to speed control switch (3). 4. Install horn switch (2) to steering wheel. 5. Connect electrical connector (1) to horn switch (2). 6. Install horn switch mounting screws (3) and tighten screws to 8 Nm (71 ins. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal > Page 7294 7. Install driver's side airbag See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Installation. 8. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). 9. Verify vehicle and system operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 7299 Cruise Control Switch: Diagrams Connector - (STEERING WHEEL) 3 WAY SWITCH-SPEED CONTROL - (STEERING WHEEL) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal Cruise Control Switch: Service and Repair Speed Control Switch - Removal REMOVAL WARNING: Disconnect and isolate the battery negative (ground) cable before beginning steering wheel removal or installation. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. This will disable the front airbag system. Failure to disconnect the battery could result in accidental front airbag module deployment and possible personal injury.Do not place a non-deployed airbag face down on a hard surface as the airbag will propel into the air if accidentally deployed, and could result in serious or fatal injury. 1. Disconnect and isolate the negative battery cable before beginning steering wheel removal. Allow the front airbag system capacitor to discharge for two minutes before removing the steering wheel or any front airbag system component. 2. Turn off ignition. 3. Remove the driver's side airbag, See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Removal. 4. Disconnect electrical connector (1) from horn switch (2). 5. Remove mounting screws (3) and horn switch (2) from steering wheel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal > Page 7302 6. Disconnect electrical connector (1) from speed control switch (3). 7. Remove screws (4) from speed control switch (3). 8. Remove speed control switch (3) from steering wheel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal > Page 7303 Cruise Control Switch: Service and Repair Speed Control Switch - Installation INSTALLATION 1. Install speed control switch (3) onto the locating pin (2) in the steering wheel. Make sure rubber seal is in place around switch. 2. Install speed control switch mounting screws (4) and tighten screws to 1.6 Nm (15 ins. lbs.). 3. Connect electrical connector (1) to speed control switch (3). 4. Install horn switch (2) to steering wheel. 5. Connect electrical connector (1) to horn switch (2). 6. Install horn switch mounting screws (3) and tighten screws to 8 Nm (71 ins. lbs.). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal > Page 7304 7. Install driver's side airbag See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Installation. 8. Connect negative battery cable, tighten nut to 5 Nm (45 in. lbs.). 9. Verify vehicle and system operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Chime/Buzzer - Description Audible Warning Device: Description and Operation Chime/Buzzer - Description DESCRIPTION The chime software is located within, and serviced with the instrument cluster. The chime warning system uses an electromechanical transducer and an electromechanical relay that are soldered onto the electronic circuit board inside of the Electro Mechanical Instrument Cluster (EMIC) to provide audible indications of various vehicle conditions that may require the attention of the vehicle operator or occupants. The EMIC also includes the hardware and software necessary to serve as the electronic body control module and is sometimes referred to as the Cab Compartment Node or CCN. The electromechanical transducer generates beep tones and chime tones, while the electromechanical relay generates click tones to emulate the sounds associated with conventional turn signal and hazard warning flasher operation. The microprocessor-based EMIC utilizes electronic chime request messages received from other modules in the vehicle over the Controller Area Network (CAN) data bus along with hard wired inputs to monitor many sensors and switches throughout the vehicle. In response to those inputs, the circuitry and programming of the EMIC allow it to control the audible outputs that are produced through its on-board transducer and relay. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Chime/Buzzer - Description > Page 7310 Audible Warning Device: Description and Operation Chime/Buzzer - Operation OPERATION CHIME WARNING SYSTEM The chime warning system operates on battery voltage received through a fuse in the Junction Block (JB) on a non-switched fused B(+) circuit so that the system may operate regardless of the ignition switch position. The chime warning system also monitors the ignition switch position so that some chime features are functional only with the ignition switch in the On position, while others are functional regardless of the ignition switch position. The chime warning system provides an audible indication to the vehicle operator or occupants under the following conditions: - Airbag Indicator Warning - The Cab Compartment Node (CCN) will generate one short chime when the ignition switch is in the On position, and an electronic message is received over the Controller Area Network (CAN) data bus from the Occupant Restraint Controller (ORC) requesting "Airbag" indicator illumination. This warning will only occur following completion of the "Airbag" indicator bulb test, and will only occur once during any ignition cycle. - Door Ajar Indicator Warning - The CCN will generate one short chime when the ignition switch is in the On position, a hard wired input is received indicating that the status of any door ajar switch has changed, and an electronic message is received over the CAN data bus indicating that the vehicle is moving. Door ajar chime occurs only if the door ajar status is true. - Door opened and - Ignition in RUN position and - Vehicle speed is present - Fasten Seat Belt Indicator Warning - The CCN will generate repetitive chimes at a slow rate to announce that a hard wired input from the seat belt switch indicates that the driver side front seat belt is not fastened with the ignition switch in the On position. The chime warning system also supports the enhanced seat belt reminder (belt-minder) when this feature is enabled. NOTE: If the vehicle is equipped with the Occupant Classification System (OCS), this will apply to the front passenger seatbelt as well. There are two different Fasten Seatbelt Reminder announcements incorporated into the cluster's logic, a Non-enhanced announcement and an Enhanced announcement. When the Enhanced announcement is DISABLED: - The cluster will chime five times (not greater than six seconds) and illuminate the Seatbelt Lamp after turning the ignition to the run/start position if the driver/passenger seatbelt is unbuckled. When the Enhanced announcement is ENABLED; - The cluster will chime continuously at a slow rate for a period of 6 seconds and illuminate the Seatbelt Lamp after turning the ignition to the run/start position if the driver/passenger seatbelt is unbuckled. After 6 seconds the chime will stop, but the Seatbelt Lamp will stay illuminated. If the ignition is in the run position for a period greater than 60 seconds, and the driver/passenger seatbelt is unbuckled, and the vehicle's speed is greater than 5 mph (8 km/h) in a forward gear, the Enhanced Fasten Seatbelt Reminder will activate. This will cause the Seatbelt Lamp to blink and a slow continuous chime to sound for 5 seconds. After 5 seconds, the chime will stop, but the lamp will remain illuminated for an additional 3 seconds. The Enhanced Seatbelt Reminder cycles for a total of 12 times (96 seconds). After the 12th time, the Seatbelt Lamp will remain on without any chime. Buckling the driver/passenger seatbelt at anytime will cancel the Fasten Seatbelt Reminder announcement. The seatbelt indicator includes a programmable enhanced seatbelt reminder or "belt-minder" feature that is enabled when the vehicle is shipped from the factory. This belt-minder feature can be disabled and enabled by the customer using a specific programming event sequence, or by the dealer using a diagnostic scan tool. - Gate Ajar Indicator Warning - The CCN will generate one short chime when the ignition switch is in the On position, a hard wired input is received indicating that the status of the liftgate ajar switch has changed (switch position has to change to true), and an electronic message is received over the CAN data bus indicating that the vehicle is moving. - Head/Park Lamps-On Warning - The CCN will generate repetitive chimes at a fast rate to indicate that hard wired inputs from the driver door ajar switch, the headlamp switch, and the ignition switch indicate that the exterior lamps are turned On with the driver side front door opened and the ignition switch in the Off position. The chimes will continue to sound until the exterior lamps are turned Off, the driver side front door is closed, or the ignition switch is turned to the On position, whichever occurs first. - Key-In-Ignition Warning - The CCN will generate repetitive chimes at a fast rate to indicate that hard wired inputs from the driver door ajar switch, the ignition switch, and the key-in ignition switch circuitry of the ignition switch indicate that the key is in the ignition in the lock position with the driver side front door open and the ignition switch in the Off position. The chimes will continue to sound until the key is removed from the ignition lock cylinder, the driver side front door is closed, or the ignition switch is turned to the On position, whichever occurs first. - Low Fuel Indicator Warning - The CCN will generate one short chime when the low fuel indicator is illuminated by the instrument cluster circuitry. This chime will only occur once during any ignition cycle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Chime/Buzzer - Description > Page 7311 - Park Brake Reminder - The CCN will generate one short chime to announce that the hard wired input from the park brake switch and a vehicle speed message input received over the CAN data bus indicate that the park brake is applied and the vehicle is moving. This chime will repeat each time the input conditions are met. - Sentry Key "Customer Learn" Mode Announcement - The CCN will generate one short chime to confirm that an electronic "Customer Learn" mode message has been received over the CAN data bus to indicate that the Sentry Key Remote Entry Module (SKREEM) is prepared for programming additional sentry key transponders. This chime feature is only active on vehicles equipped with the optional Sentry Key system, and sold in a market where "Customer Learn" programming is an allowed feature. - Turn Signal/Hazard Warning Flasher Emulation - The CCN relay will generate repetitive clicks at a slow rate to emulate an electromechanical flasher when the turn signal or hazard warning system are operating. The CCN relay will generate repetitive clicks at a fast rate to indicate that the right or left turn signal are operating with one or more bulbs inoperative. In either case, the clicks will continue until the turn signal and hazard warning systems are turned off. - Turn Signal On Warning - The CCN will generate repetitive chimes at a slow rate to indicate that a turn signal has been active continuously for 1.6 kilometers (1 mile) with the vehicle speed greater than 22 kilometers-per-hour (15 miles-per hour). Vehicles built for markets other than the United States and Canada have a revised distance threshold of 4 kilometers for this feature. The chime will continue until the turn signal input becomes inactive or until the vehicle speed message indicates that the speed is less than 22 kilometers-per-hour (15 miles-per-hour), whichever occurs first. The hazard warning flashers will not activate this chime feature. - Warning Indicator Announcement - The CCN will generate one short chime each time the Malfunction Indicator or MIL lamp is illuminated by the instrument cluster circuitry. The check gauges indicator may be illuminated when any critical engine or transmission systems are operating outside of their normal parameters. The instrument cluster monitors electronic messages received over the CAN data bus to determine when to illuminate the check gauges indicator. The CCN provides chime service for all available features in the chime warning system. The CCN relies upon its internal programming, numerous hard wired inputs, and electronic message inputs received from other modules over the CAN data bus network to provide the chime warning system features. The internal programming of the CCN determines the priority of each chime request input that is received, as well as the rate and duration of each chime that is to be generated. The hard wired chime warning system inputs to the CCN may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CCN, the CAN data bus, or the electronic messages received by the CCN from other modules. The most reliable, efficient and accurate means to diagnose the CCN, the CAN/LIN data bus, or the electronic message inputs used for the chime warning system requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Chime/Buzzer - Brake/Park Brake Indicator Audible Warning Device: Testing and Inspection Chime/Buzzer - Brake/Park Brake Indicator BRAKE/PARK BRAKE INDICATOR The brake/park brake indicator illuminates when the parking brake is applied with the ignition switch turned to the ON position (Refer to the PARK BRAKE SWITCH TEST table. The same lamp will also illuminate if one of the two (hydraulic or ABS) service brake systems fail when the brake pedal is applied. PARK BRAKE SWITCH TEST TO TEST THE SYSTEM: - As the ignition switch is turned to the START position, the lamp should light. - Turn ignition switch to the ON position and apply the parking brake. The lamp should light. IF LAMPS FAILS TO LIGHT, INSPECT FOR: - A broken or disconnected wire at the switch - Defective switch - A burned out Light Emitting Diode (LED) - A damaged circuit board To test the service brake warning system, refer to Brakes, Diagnosis and Testing, Base Brake System Diagnosis Charts, Red Brake Warning Lamp. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Chime/Buzzer - Brake/Park Brake Indicator > Page 7314 Audible Warning Device: Testing and Inspection Chime/Buzzer - Chime/Buzzer System CHIME/BUZZER SYSTEM The hard wired chime warning system inputs to the Electro Mechanical Instrument Cluster (EMIC), as well as other hard wired circuits for this system may be diagnosed and tested using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the Controller Area Network (CAN) data bus, or the electronic message inputs used by the EMIC to provide chime warning system service. The most reliable, efficient, and accurate means to diagnose the EMIC, the CAN data bus, and the electronic message inputs for the chime warning system requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Chime/Buzzer - Brake/Park Brake Indicator > Page 7315 Audible Warning Device: Testing and Inspection Chime/Buzzer - Fasten Seat Belts FASTEN SEAT BELTS To test the fasten seat belts function, turn the ignition switch to the ON position with the driver's seat belt unbuckled and fully retracted. The seat belt warning lamp should light for four to eight seconds and the tone should sound three to five times. If the lamp does not light, check the connection at the seat belt retractor. Replace as necessary. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7320 It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7321 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7322 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7323 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7324 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7325 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7326 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7327 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7328 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7329 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7330 Cigarette Lighter: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7331 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7332 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 7333 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams Compass: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY MODULE-COMPASS - (INSTRUMENT PANEL) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Calibration Compass: Adjustments Compass Calibration COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDA's, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. The electronic compass unit features a continuous self-calibrating feature. This feature automatically updates the compass calibration as the vehicle is driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or the Electronic Vehicle Information Center (EVIC) displays "CAL", perform the following calibration procedure. Also, any time a new RCM is installed, it must be calibrated using this procedure. Calibrate the compass manually as follows: NOTE: Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. 1. Start the engine but leave the vehicle in "PARK". 2. Continue to depress and release the STEP button (28) until the "Personal Settings" menu is displayed. 3. Once in the "Personal Settings" menu depress and release the STEP button (28) several times until "Calibrate Compass (Yes)" is displayed. 4. A long (longer than two seconds) STEP button press will place the compass in calibration mode. The "Cal" indicator will change from flashing to on continuously in the EVIC display (29) to indicate that the compass is now in the calibration mode and that the vehicle can now be driven to calibrate. (A short STEP button press from the "Calibrate Compass (Yes)" screen will exit the EVIC Customer Programmable features, and return it to its normal operating mode). 5. To complete the compass calibration, drive the vehicle in one or more complete 360 degree circles under 5 mph (8 km/h) in an area free of large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines, until the "CAL" indicator turns off. The compass will now function normally. NOTE: If the compass display indicates an inaccurate compass heading or the display is locked up, the RCM may be inoperative or the vehicle may need to be demagnetized. Perform the Compass Demagnetizing Procedure prior to performing any system diagnosis, See: Driver/Vehicle Information Display/Adjustments . NOTE: If the compass display indicates dashes "- -" the RCM may be inoperative or the vehicle may need to be demagnetized. Perform the Compass Demagnetizing Procedure prior to performing any system diagnosis, See: Driver/Vehicle Information Display/Adjustments . NOTE: If the "CAL" message remains in the display or if the compass heading is inaccurate following the calibration procedure and there are no internal compass faults, either there is excessive magnetism near the compass, or the unit is inoperative. Repeat the calibration procedure at least one more time prior to performing any system diagnosis. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the calibration procedure in another location. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Compass Calibration > Page 7339 Compass: Adjustments Compass Variance Adjustment COMPASS VARIANCE ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give inaccurate readings. To optimize compass accuracy, the compass variance should be properly set according to the compass variance map zone for the region that the vehicle is in. To set the compass variance: 1. Using the Variance Settings map, find your geographic location and note the zone number. 2. Turn the ignition switch to the On position. 3. Continue to depress and release the STEP button (28) until the "Personal Settings" menu is displayed. 4. Once in the "Personal Settings" menu depress and release the STEP button (28) several times until "Compass Variance" is displayed. The "Compass Variance" message and the current variance zone number will be displayed. The default variance zone is 8. NOTE: During programming, the Zone value will wrap around from Zone 15 to Zone 1. 5. To change the zone, press and hold (longer than two seconds) the STEP button to increment the variance one step. Repeat as necessary, with individual long (longer than two seconds) STEP button presses for each increment, until the desired variance is achieved. 6. To exit the Variance Programming, press the STEP button with a short (less than one second) button press. 7. Confirm that the correct directions are now indicated by the compass. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Page 7340 Compass: Service and Repair COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 3. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 4. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 5. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 6. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 7. Calibrate the compass, See: Driver/Vehicle Information Display/Adjustments and adjust the compass variance, See: Driver/Vehicle Information Display/Adjustments. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. How to Use Wiring Diagrams HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7346 It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7347 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7348 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7349 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7350 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7351 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7352 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7353 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7354 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7355 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7356 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7357 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7358 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7359 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7360 Driver/Vehicle Information Display: Connector Views Electronic Overhead Module C1 (Headliner) 3 Way Connector C1 - (HEADLINER) 3 WAY MODULE-ELECTRONIC OVERHEAD - (HEADLINER) 3 WAY Electronic Overhead Module C2 (Headliner) 4 Way Connector C2 - (HEADLINER) 4 WAY MODULE-ELECTRONIC OVERHEAD - (HEADLINER) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7361 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Electronic Vehicle Information Center - Description Driver/Vehicle Information Display: Description and Operation Electronic Vehicle Information Center - Description DESCRIPTION The base instrument cluster can be identified by the single TRIP SHAFT button (18) located to the left of the Temperature Gauge (3). The odometer display (15) doubles as the outside air temperature display when selected by toggling through the odometer menu using the TRIP SHAFT button. The Electronic Vehicle Information Center (EVIC) features a driver-interactive display (29). The display is located in the lower left part of the instrument cluster below the fuel and engine temperature gauges (1 and 3). This system conveniently allows the driver to select a variety of useful information by pressing the STEP button (28) to the right of the EVIC display. The EVIC displays information related to the following: - System Status - Vehicle information warning message displays - Personal Settings (customer programmable features) - Compass display - Outside temperature display - Trip computer functions - Connect(TM) hands-free communication system displays - If Equipped - Navigation system screens - If Equipped - Audio mode display The EVIC system is comprised of several different components. Those components are: - Instrument Cluster - EVIC STEP Button Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Electronic Vehicle Information Center - Description > Page 7364 - Ambient Temperature Sensor - Remote Compass Module (RCM) - Controller Area Network (CAN) Data Bus - Local Interface Network (LIN) Data Bus The EVIC display and STEP button are part of the Instrument Cluster assembly and cannot be serviced as separate components. If the display or button are inoperative the complete Instrument Cluster assembly must be replaced, See: Instrument Cluster / Carrier/Service and Repair/Instrument Cluster - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Electronic Vehicle Information Center - Description > Page 7365 Driver/Vehicle Information Display: Description and Operation Electronic Vehicle Information Center - Operation OPERATION The Electronic Vehicle Information Center (EVIC) uses both non-switched and ignition switched sources of battery current so that some of its features remain operational at any time, while others may only operate with the ignition switch in the On position. When the ignition switch is turned to the On position, the EVIC display (29) will return to the last function being displayed before the ignition was turned to the Off position. The EVIC system is comprised of several different components that communicate over the Controller Area Network (CAN) and Local Interface Network (LIN) Data Buses. If the system is inoperative a scan tool and the appropriate diagnostic information must be used to diagnose the system and related data buses. The instrument cluster STEP button (28) is used to operate the different functions of the EVIC system. Pressing and releasing the STEP button will scroll through the following displays: - Compass/Temperature/Audio - Average Fuel Economy - Distance to Empty - Elapsed Time - Personal Settings Once a particular system is displayed, short and long presses of the STEP button will move the EVIC through the system menu. Pressing and holding the STEP button once will clear the reset table function currently being displayed. Reset will only occur if a resettable function is currently being displayed. To reset all resettable functions, press and release the STEP button a second time within 3 seconds of resetting the currently displayed function (Reset ALL will be displayed during this 3 second window). EVIC DISPLAY MODES SYSTEM STATUS MODE System display mode displays warnings and user interaction messages on the EVIC display (29). The driver can scroll to view multiple messages by using the STEP button. When the appropriate conditions exist, the EVIC displays the following messages: - Turn Signal On (with a continuous warning chime) - Left Front Turn Signal Lamp Out (with a single chime) - Left Rear Turn Signal Lamp Out (with a single chime) - Right Front Turn Signal Lamp Out (with a single chime) - Right Rear Turn Signal Lamp Out (with a single chime) - Personal Settings Not Available - Vehicle Not in Park (automatic transmissions) or vehicle in motion (manual transmissions) - Left/Right Front Door Ajar (one or more, with a single chime if speed is above 1 mph (1.6 km/h)) - Left/Right Rear Door Ajar (one or more, with a single chime if speed is above 1 mph (1.6 km/h)) - Door(s) Ajar (with a single chime if vehicle is in motion) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Electronic Vehicle Information Center - Description > Page 7366 - Trunk Ajar (with a single chime) - Headlamps On/Lights On With Key Out Of Ignition. COMPASS/TEMPERATURE/AUDIO Compass heading and outside temperature are displayed at the top of the EVIC display screen. On the lower half of the screen the audio mode is displayed along with the odometer. One of eight compass headings to indicate the direction the vehicle is facing (N, S, E, W, NE, NW, SE, SW) and to select one of 15 compass variance settings. Outside temperature is displayed in °C (degrees Celsius) or °F (degrees Fahrenheit). Audio mode can display any one of 12 radio station preset frequencies, CD disc number, CD track number, tape, and one of 200 Satellite Radio Channels - if equipped. For additional information regarding the compass, refer to Personal Settings (Customer Programmable Features). AVERAGE FUEL ECONOMY Shows the average fuel economy since the last reset. When the fuel economy is reset, the display will read "RESET" or show dashes for two seconds. Then, the history information will be erased, and the averaging will continue from where it was before the reset. DISTANCE TO EMPTY (DTE) NOTE: Significant changes in driving style or vehicle loading will greatly affect the actual drivable distance of the vehicle, regardless of the DTE displayed value. Shows the estimated distance that can be travelled with the fuel remaining in the tank. This estimated distance is determined by a weighted average of the instantaneous and average fuel economy, according to the current fuel tank level. This is not resettable. When the DTE value is less than 30 miles (48 kilometers) estimated driving distance, the DTE display will change to a text display of "LOW FUEL". This display will continue until the vehicle runs out of fuel. Adding a significant amount of fuel to the vehicle will turn off the "LOW FUEL" text and a new DTE value will be displayed, based on the current values in the DTE calculation and the current fuel tank level. ELAPSED TIME Shows the total elapsed time of travel since the last reset when the ignition switch is in the ACC position. Elapsed time will increment when the ignition switch is in the ON or START position. HANDS FREE TELEPHONE MODE - IF EQUIPPED Provides the following information and features for the optional hands-free communications system: - Phone status: idle, voice mail, roaming, battery strength and signal strength in increments of 20 percent - Call status: Incoming call, connecting, connected, air time in minutes and seconds, call ended, busy, call failed, roaming and no phone connection - Caller ID phone number display PERSONAL SETTINGS MODE (CUSTOMER PROGRAMMABLE FEATURES) Allows the driver to set and recall features when the transmission is in Park by pressing and releasing the STEP button until Personal Settings is displayed in the EVIC. The following personal settings can be set and recalled: - Language: English, Spanish and French (domestic markets) German and Italian (export markets) - Lock doors automatically at 15 mph (24 km/h), On or Off - Unlock door automatically on exit, On or Off - Remote Keyless Entry unlock driver door on first press or unlock all doors on first press - Sound horn with Remote Keyless Entry Lock, On or Off - Turn headlamps on with Remote Keyless Entry Lock, On or Off - Delay turning headlamps off for 0, 30, 60 or 90 seconds - Key-Off Power Delay (delay power off to accessories until exit off, 45-seconds maximum, 5-minute maximum, 10-minute maximum) - Illuminated Approach - Turn headlamps on with Remote Keyless Entry Unlock, Off or 30, 60 or 90 seconds - Display units in English or Metric - Compass Variance Setting 1 through 15 - Calibrate Compass Yes/No Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 7367 Driver/Vehicle Information Display: Testing and Inspection ELECTRONIC VEHICLE INFORMATION CENTER CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDA's, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. The Electronic Vehicle Information Center (EVIC) data is obtained from several components on the Controller Area Network (CAN) and Local Interface Network (LIN) Data Bus circuits. The EVIC will not function properly if the bus messages from any of these components is not received. If no EVIC data is displayed or the display indicates dashes "- -", check the CAN Data Bus circuit communications, the Instrument Cluster functions, the Remote Compass Module (RCM) and the Totally Integrated Power Module (TIPM). The use of a scan tool and the proper diagnostic procedures information are recommended for further testing of the EVIC, the RCM, the CAN Data Bus and Local Interface Network (LIN) Data Bus circuits. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Compass Calibration Driver/Vehicle Information Display: Adjustments Compass Calibration COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not place any electronic devices (cell phones, laptop computers, PDA's, portable DVD players, etc), on or near the instrument panel as the Remote Compass Module (RCM) performance may be effected. Do not use magnetic tools when servicing the RCM. The electronic compass unit features a continuous self-calibrating feature. This feature automatically updates the compass calibration as the vehicle is driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or the Electronic Vehicle Information Center (EVIC) displays "CAL", perform the following calibration procedure. Also, any time a new RCM is installed, it must be calibrated using this procedure. Calibrate the compass manually as follows: NOTE: Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. 1. Start the engine but leave the vehicle in "PARK". 2. Continue to depress and release the STEP button (28) until the "Personal Settings" menu is displayed. 3. Once in the "Personal Settings" menu depress and release the STEP button (28) several times until "Calibrate Compass (Yes)" is displayed. 4. A long (longer than two seconds) STEP button press will place the compass in calibration mode. The "Cal" indicator will change from flashing to on continuously in the EVIC display (29) to indicate that the compass is now in the calibration mode and that the vehicle can now be driven to calibrate. (A short STEP button press from the "Calibrate Compass (Yes)" screen will exit the EVIC Customer Programmable features, and return it to its normal operating mode). 5. To complete the compass calibration, drive the vehicle in one or more complete 360 degree circles under 5 mph (8 km/h) in an area free of large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines, until the "CAL" indicator turns off. The compass will now function normally. NOTE: If the compass display indicates an inaccurate compass heading or the display is locked up, the RCM may be inoperative or the vehicle may need to be demagnetized. Perform the Compass Demagnetizing Procedure prior to performing any system diagnosis, See: . NOTE: If the compass display indicates dashes "- -" the RCM may be inoperative or the vehicle may need to be demagnetized. Perform the Compass Demagnetizing Procedure prior to performing any system diagnosis, See: . NOTE: If the "CAL" message remains in the display or if the compass heading is inaccurate following the calibration procedure and there are no internal compass faults, either there is excessive magnetism near the compass, or the unit is inoperative. Repeat the calibration procedure at least one more time prior to performing any system diagnosis. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the calibration procedure in another location. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Compass Calibration > Page 7370 Driver/Vehicle Information Display: Adjustments Compass Variance Adjustment COMPASS VARIANCE ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give inaccurate readings. To optimize compass accuracy, the compass variance should be properly set according to the compass variance map zone for the region that the vehicle is in. To set the compass variance: 1. Using the Variance Settings map, find your geographic location and note the zone number. 2. Turn the ignition switch to the On position. 3. Continue to depress and release the STEP button (28) until the "Personal Settings" menu is displayed. 4. Once in the "Personal Settings" menu depress and release the STEP button (28) several times until "Compass Variance" is displayed. The "Compass Variance" message and the current variance zone number will be displayed. The default variance zone is 8. NOTE: During programming, the Zone value will wrap around from Zone 15 to Zone 1. 5. To change the zone, press and hold (longer than two seconds) the STEP button to increment the variance one step. Repeat as necessary, with individual long (longer than two seconds) STEP button presses for each increment, until the desired variance is achieved. 6. To exit the Variance Programming, press the STEP button with a short (less than one second) button press. 7. Confirm that the correct directions are now indicated by the compass. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures Driver/Vehicle Information Display: Procedures COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 3. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 4. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 5. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 6. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 7. Calibrate the compass, See: Adjustments and adjust the compass variance, See: Adjustments. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 7373 Driver/Vehicle Information Display: Removal and Replacement Electronic Vehicle Information Center - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: RHD model shown in illustration. LHD model similar. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel upper panel, See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Pad - Removal. 3. Remove the screws (6) securing the Remote Compass Module (RCM) (5) to the instrument panel. 4. Disconnect the RCM electrical connector (1) and remove the RCM from the vehicle. Electronic Vehicle Information Center - Installation INSTALLATION NOTE: RHD model shown in illustration. LHD model similar. 1. Position the Remote Compass Module (RCM) (5) on top of the instrument panel. 2. Install the screws (6) that secure the RCM to the instrument panel. 3. Connect the RCM electrical connector (1). 4. Install the instrument panel upper panel, See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Pad - Installation. 5. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 7374 Driver/Vehicle Information Display: Tools and Equipment SPECIAL TOOLS DEGAUSSING TOOL 6029 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation Fuel Gauge Module: Customer Interest Instruments - Fuel Gauge Fluctuation NUMBER: 08-024-10 GROUP: Electrical DATE: September 22, 2010 SUBJECT: Fuel Gauge Fluctuation OVERVIEW: This Bulletin involves replacing the fuel sending unit, clocking the fuel module and installing a fuel jumper hose. MODELS: 2007 - 2010 (PM) Caliber (FWD Only) 2007 - 2010 (MK) Compass / Patriot (FWD Only) SYMPTOM/CONDITION: The customer may complain that the fuel gauge is not accurate or fluctuates at 3/4 of a tank or above. DIAGNOSIS: Some customers may experience the condition described above. Preform the repair as described below. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Removal > Front Wheel Drive Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 7384 NOTE: Mark the sending unit at the 4:00 position with 12:00 pointing to the rear of the vehicle. 2. Remove the fuel pump sending unit from the Pump module. 3. Install New Sender to the Fuel Pump Module. 4. Install Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Installation > Front Wheel Drive NOTE: Clock the Fuel Module to the 2:00 position Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 7385 5. Install the jumper hose kit 6. Re-Connect battery 7. Start vehicle and check for leaks 8. Re-install Fuel Pump Cover 9. Re-install padding and rear seat bottom 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation Fuel Gauge Module: All Technical Service Bulletins Instruments - Fuel Gauge Fluctuation NUMBER: 08-024-10 GROUP: Electrical DATE: September 22, 2010 SUBJECT: Fuel Gauge Fluctuation OVERVIEW: This Bulletin involves replacing the fuel sending unit, clocking the fuel module and installing a fuel jumper hose. MODELS: 2007 - 2010 (PM) Caliber (FWD Only) 2007 - 2010 (MK) Compass / Patriot (FWD Only) SYMPTOM/CONDITION: The customer may complain that the fuel gauge is not accurate or fluctuates at 3/4 of a tank or above. DIAGNOSIS: Some customers may experience the condition described above. Preform the repair as described below. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Removal > Front Wheel Drive Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 7391 NOTE: Mark the sending unit at the 4:00 position with 12:00 pointing to the rear of the vehicle. 2. Remove the fuel pump sending unit from the Pump module. 3. Install New Sender to the Fuel Pump Module. 4. Install Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Installation > Front Wheel Drive NOTE: Clock the Fuel Module to the 2:00 position Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 7392 5. Install the jumper hose kit 6. Re-Connect battery 7. Start vehicle and check for leaks 8. Re-install Fuel Pump Cover 9. Re-install padding and rear seat bottom 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation Fuel Gauge Sender: Customer Interest Instruments - Fuel Gauge Fluctuation NUMBER: 08-024-10 GROUP: Electrical DATE: September 22, 2010 SUBJECT: Fuel Gauge Fluctuation OVERVIEW: This Bulletin involves replacing the fuel sending unit, clocking the fuel module and installing a fuel jumper hose. MODELS: 2007 - 2010 (PM) Caliber (FWD Only) 2007 - 2010 (MK) Compass / Patriot (FWD Only) SYMPTOM/CONDITION: The customer may complain that the fuel gauge is not accurate or fluctuates at 3/4 of a tank or above. DIAGNOSIS: Some customers may experience the condition described above. Preform the repair as described below. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Removal > Front Wheel Drive Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 7401 NOTE: Mark the sending unit at the 4:00 position with 12:00 pointing to the rear of the vehicle. 2. Remove the fuel pump sending unit from the Pump module. 3. Install New Sender to the Fuel Pump Module. 4. Install Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Installation > Front Wheel Drive NOTE: Clock the Fuel Module to the 2:00 position Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 7402 5. Install the jumper hose kit 6. Re-Connect battery 7. Start vehicle and check for leaks 8. Re-install Fuel Pump Cover 9. Re-install padding and rear seat bottom 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation Fuel Gauge Sender: All Technical Service Bulletins Instruments - Fuel Gauge Fluctuation NUMBER: 08-024-10 GROUP: Electrical DATE: September 22, 2010 SUBJECT: Fuel Gauge Fluctuation OVERVIEW: This Bulletin involves replacing the fuel sending unit, clocking the fuel module and installing a fuel jumper hose. MODELS: 2007 - 2010 (PM) Caliber (FWD Only) 2007 - 2010 (MK) Compass / Patriot (FWD Only) SYMPTOM/CONDITION: The customer may complain that the fuel gauge is not accurate or fluctuates at 3/4 of a tank or above. DIAGNOSIS: Some customers may experience the condition described above. Preform the repair as described below. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Removal > Front Wheel Drive Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 7408 NOTE: Mark the sending unit at the 4:00 position with 12:00 pointing to the rear of the vehicle. 2. Remove the fuel pump sending unit from the Pump module. 3. Install New Sender to the Fuel Pump Module. 4. Install Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Installation > Front Wheel Drive NOTE: Clock the Fuel Module to the 2:00 position Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 7409 5. Install the jumper hose kit 6. Re-Connect battery 7. Start vehicle and check for leaks 8. Re-install Fuel Pump Cover 9. Re-install padding and rear seat bottom 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module (AWD) Fuel Gauge Sender: Locations Fuel Pump Module (AWD) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module (AWD) > Page 7412 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module (AWD) > Page 7413 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way Fuel Gauge Sender: Diagrams Fuel Pump Module (FWD) (Body) 4 Way Connector (FWD) - (BODY) 4 WAY MODULE-FUEL PUMP (FWD) - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way > Page 7416 Fuel Gauge Sender: Diagrams Fuel Pump Module C1 (AWD) (Body) 5 Way Connector C1 (AWD) - (BODY) 5 WAY MODULE-FUEL PUMP (AWD) - (BODY) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way > Page 7417 Fuel Gauge Sender: Diagrams Fuel Pump Module C2 (AWD) (Body) 2 Way Connector C2 (AWD) - (BODY) 2 WAY MODULE-FUEL PUMP (AWD) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Gauge Sender: Description and Operation Fuel Pump Module - Description DESCRIPTION - FUEL PUMP MODULE The fuel pump module is located on the top left side of the fuel tank. The fuel pump module contains the following components: - Mounting flange - Electric fuel pump - Fuel pump reservoir - Inlet strainer - Fuel pressure regulator - Fuel level sending unit - Fuel filter The fuel level sending unit (3) is the only serviceable component of the fuel pump module. If the electric fuel pump, fuel pressure regulator or fuel filter requires service, the fuel pump module must be replaced as an assembly. DESCRIPTION The fuel pump module is installed in the top of the fuel tank. The fuel pump module contains the following: - Electric fuel pump - Fuel pump reservoir Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description > Page 7420 - Inlet strainer - Fuel pressure regulator - Fuel gauge sending unit - Fuel supply line connection - Fuel Filter NOTE: The fuel level sending unit is the only serviceable item. If the fuel pump, fuel pressure regulator or fuel filters need service, replace the fuel pump module as an assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description > Page 7421 Fuel Gauge Sender: Description and Operation Fuel Pump Module - Operation OPERATION - FUEL PUMP MODULE An electric fuel pump is located within the fuel pump module. The electric fuel pump is a positive displacement, immersible pump with a permanent magnet electric motor capable of creating 860 kPa (125 psi) of operating pressure. The fuel pressure regulator limits fuel pressure to 400 kPa (58 psi). The fuel gauge is controlled by the instrument cluster circuit board based upon cluster programming and a hard wired input received by the cluster from the fuel level sending unit on the module in the fuel tank. The instrument cluster continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. This information is available to other vehicle control modules via the Controller Area Network (CAN) data bus. Fuel gauge diagnosis is conducted as part ofthe instrument cluster circuitry. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Gauge Sender: Service and Repair Fuel Pump Module - Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. 1. Perform Fuel System Pressure Release procedure. See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose. 3. Remove the negative battery cable. 4. Remove the rear seat cushion. 5. Rear seat cushion loose. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 7424 6. Remove plastic cover. 7. Clean top of tank to remove loose dirt and debris. 8. Use special tool #9340 to remove left side module lock ring. 9. Note the fuel pump location on the top of the fuel tank. NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 7425 10. Pull module up out of fuel tank, make sure that you do not spill fuel inside of vehicle. 11. Drain fuel from fuel pump module. Do not spill fuel in interior of vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 7426 Fuel Gauge Sender: Service and Repair Fuel Pump Module - Installation INSTALLATION NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. 1. Wipe seal area of tank clean. Place a new seal between the tank threads and the pump module opening. 2. Install module. 3. Position fuel pump module in tank. Make sure the alignment tab lines up on the fuel tank and pump module for Gas or Diesel fuel tanks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 7427 4. While holding the pump module in position, install lock ring and use special tool Spanner Wrench #9340 to tighten lock ring. 5. Install plastic cover. 6. Install rear cushion. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 7428 7. Install the negative battery cable. 8. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. 9. Fill fuel tank with clean fuel. Use the Scan Tool to pressurize the system and check for leaks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair To reset the oil change indicator (after performing the scheduled maintenance) refer to the following procedure. 1. Turn the ignition switch to the ON position (Do not start the engine). 2. Fully depress the accelerator pedal slowly three times within 10 seconds. 3. Turn the ignition switch to the OFF/LOCK position. NOTE: If the indicator message illuminates when you start the vehicle, the oil change indicator system did not reset. If necessary, repeat this procedure. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 7435 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 7436 Oil Pressure Sender: Diagrams Connector - (POWERTRAIN) 2 WAY SWITCH-ENGINE OIL PRESSURE - (POWERTRAIN) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor Description Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Description DESCRIPTION The ambient temperature sensor is a variable resistor type sensor. It is mounted in the lower radiator grille opening, below the bumper and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor Description > Page 7442 Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the Totally Integrated Power Module (TIPM). Based upon the resistance in the sensor, the instrument cluster or Cab Compartment Node (CCN) display senses a specific voltage on the Controller Area Network (CAN) data bus circuit, which corresponds to a specific temperature. The compass/temperature display unit then displays the proper ambient temperature. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Description and Operation > Page 7443 Outside Temperature Display Sensor: Testing and Inspection AMBIENT TEMPERATURE SENSOR The thermometer function is supported by the ambient temperature sensor, the Totally Integrated Power Module (TIPM), the Controller Area Network (CAN) data bus circuit, and the instrument cluster or Cab Compartment Node (CCN) compass/temperature display unit. NOTE: The system displays the last known temperature when starting the vehicle and may take some time/mileage to update to an accurate current reading, up to 5 minutes at a maintained speed above 40 mph (64.3 kph). Customers with very short commutes may not get an updated reading before the vehicle is turned off, or if the ignition does not remain in the OFF position for more than 255 minutes (4hrs. 15min.). This strategy was intended to eliminate wildly fluctuating readings and may cause some customer confusion leading to unnecessary diagnostics/parts replacements. If the display shows " _ _ _ ", there is an OPEN or SHORT CIRCUIT that must be repaired. The ambient temperature sensor can be diagnosed using the following Sensor Test. SENSOR TESTING 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. 2. Disconnect the ambient temperature sensor wire harness connector. 3. Measure the resistance of the ambient temperature sensor. At room temperature (approx. 20° C (68°F)), the sensor resistance should be between 9-11 Kilo Ohms (9000-11000 ohms). The sensor resistance should read between these two values. If OK, refer to the appropriate diagnostic information to continue diagnosis of the Totally Integrated Power Module (TIPM), the Controller Area Network (CAN) data bus circuit, and the instrument cluster or CCN. If not OK, replace the inoperative ambient temperature sensor. The most reliable, efficient and accurate means to diagnose the ambient temperature circuit requires the use of a scan tool and the proper diagnostic procedure information. Refer to wiring for the appropriate information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor - Removal Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a suitable tool, release the push pin type retainer that secures the ambient temperature sensor to the lower left side of the front bumper. 3. Disconnect the wire harness connector (1) from the ambient temperature sensor (2). 4. Remove the ambient temperature sensor from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor - Removal > Page 7446 Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor Installation INSTALLATION 1. Connect the wire harness connector (1) to the ambient temperature sensor (2). 2. Position the ambient temperature sensor in the vehicle. 3. Install the push pin type retainer that secures the ambient temperature sensor to the lower left side of the front bumper. 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 7450 Parking Brake Warning Switch: Diagrams Connector - (INSTRUMENT PANEL) 1 WAY SWITCH-PARKING BRAKE - (INSTRUMENT PANEL) 1 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation Fuel Gauge Module: Customer Interest Instruments - Fuel Gauge Fluctuation NUMBER: 08-024-10 GROUP: Electrical DATE: September 22, 2010 SUBJECT: Fuel Gauge Fluctuation OVERVIEW: This Bulletin involves replacing the fuel sending unit, clocking the fuel module and installing a fuel jumper hose. MODELS: 2007 - 2010 (PM) Caliber (FWD Only) 2007 - 2010 (MK) Compass / Patriot (FWD Only) SYMPTOM/CONDITION: The customer may complain that the fuel gauge is not accurate or fluctuates at 3/4 of a tank or above. DIAGNOSIS: Some customers may experience the condition described above. Preform the repair as described below. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Removal > Front Wheel Drive Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 7460 NOTE: Mark the sending unit at the 4:00 position with 12:00 pointing to the rear of the vehicle. 2. Remove the fuel pump sending unit from the Pump module. 3. Install New Sender to the Fuel Pump Module. 4. Install Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Installation > Front Wheel Drive NOTE: Clock the Fuel Module to the 2:00 position Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 7461 5. Install the jumper hose kit 6. Re-Connect battery 7. Start vehicle and check for leaks 8. Re-install Fuel Pump Cover 9. Re-install padding and rear seat bottom 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation Fuel Gauge Module: All Technical Service Bulletins Instruments - Fuel Gauge Fluctuation NUMBER: 08-024-10 GROUP: Electrical DATE: September 22, 2010 SUBJECT: Fuel Gauge Fluctuation OVERVIEW: This Bulletin involves replacing the fuel sending unit, clocking the fuel module and installing a fuel jumper hose. MODELS: 2007 - 2010 (PM) Caliber (FWD Only) 2007 - 2010 (MK) Compass / Patriot (FWD Only) SYMPTOM/CONDITION: The customer may complain that the fuel gauge is not accurate or fluctuates at 3/4 of a tank or above. DIAGNOSIS: Some customers may experience the condition described above. Preform the repair as described below. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Removal > Front Wheel Drive Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 7467 NOTE: Mark the sending unit at the 4:00 position with 12:00 pointing to the rear of the vehicle. 2. Remove the fuel pump sending unit from the Pump module. 3. Install New Sender to the Fuel Pump Module. 4. Install Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Installation > Front Wheel Drive NOTE: Clock the Fuel Module to the 2:00 position Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Gauge Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Module: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 7468 5. Install the jumper hose kit 6. Re-Connect battery 7. Start vehicle and check for leaks 8. Re-install Fuel Pump Cover 9. Re-install padding and rear seat bottom 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Testing and Inspection Seat Belt Reminder Lamp: Testing and Inspection ENHANCED SEATBELT REMINDER PROGRAMMING The seatbelt indicator also includes a programmable enhanced seatbelt reminder or "belt-minder" feature that is enabled when the vehicle is shipped from the factory. This belt-minder feature provides extended and modified visual seatbelt indicator and audible chime warning responses to an unbuckled driver side or both driver and passenger front seat belts. The belt-minder feature may be disabled or enabled by the customer using the programming sequence that follows, or by the dealer using a diagnostic scan tool. CUSTOMER PROGRAMMING SEQUENCE NOTE: The following sequence of events must occur within sixty (60) seconds of the ignition switch being placed in the On position in order for the programming to be completed successfully. Even if the vehicle is equipped with both driver and passenger side front seat belt switches, this programming sequence MUST be performed using the driver side front seat belt. The passenger side front seat belt switch has no programming functionality. 1. With all doors closed and the ignition switch in any position except On or Start, buckle the driver side front seat belt. 2. Turn the ignition switch to the On position and wait for the seatbelt indicator reminder function to conclude (about six seconds). 3. Unbuckle and buckle the driver side front seat belt three or more times, ending with the belt buckled. NOTE: The occupant must be sure to fully retract the seatbelt each time during this cycle because the actual switch is located in the seatbelt retractor and not the buckle. Each time the seatbelt is buckled or unbuckled, and fully retracted, the seatbelt indicator will illuminate or turn OFF, depending on switch state. 4. Turn the ignition switch to any position except On or Start to toggle the belt-minder feature from its current setting (from active to inactive, or from inactive to active). A single chime tone will provide an audible confirmation that the programming sequence has been successfully completed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation Fuel Gauge Sender: Customer Interest Instruments - Fuel Gauge Fluctuation NUMBER: 08-024-10 GROUP: Electrical DATE: September 22, 2010 SUBJECT: Fuel Gauge Fluctuation OVERVIEW: This Bulletin involves replacing the fuel sending unit, clocking the fuel module and installing a fuel jumper hose. MODELS: 2007 - 2010 (PM) Caliber (FWD Only) 2007 - 2010 (MK) Compass / Patriot (FWD Only) SYMPTOM/CONDITION: The customer may complain that the fuel gauge is not accurate or fluctuates at 3/4 of a tank or above. DIAGNOSIS: Some customers may experience the condition described above. Preform the repair as described below. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Removal > Front Wheel Drive Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 7481 NOTE: Mark the sending unit at the 4:00 position with 12:00 pointing to the rear of the vehicle. 2. Remove the fuel pump sending unit from the Pump module. 3. Install New Sender to the Fuel Pump Module. 4. Install Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Installation > Front Wheel Drive NOTE: Clock the Fuel Module to the 2:00 position Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 7482 5. Install the jumper hose kit 6. Re-Connect battery 7. Start vehicle and check for leaks 8. Re-install Fuel Pump Cover 9. Re-install padding and rear seat bottom 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation Fuel Gauge Sender: All Technical Service Bulletins Instruments - Fuel Gauge Fluctuation NUMBER: 08-024-10 GROUP: Electrical DATE: September 22, 2010 SUBJECT: Fuel Gauge Fluctuation OVERVIEW: This Bulletin involves replacing the fuel sending unit, clocking the fuel module and installing a fuel jumper hose. MODELS: 2007 - 2010 (PM) Caliber (FWD Only) 2007 - 2010 (MK) Compass / Patriot (FWD Only) SYMPTOM/CONDITION: The customer may complain that the fuel gauge is not accurate or fluctuates at 3/4 of a tank or above. DIAGNOSIS: Some customers may experience the condition described above. Preform the repair as described below. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Removal > Front Wheel Drive Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 7488 NOTE: Mark the sending unit at the 4:00 position with 12:00 pointing to the rear of the vehicle. 2. Remove the fuel pump sending unit from the Pump module. 3. Install New Sender to the Fuel Pump Module. 4. Install Fuel Pump Module using procedures found in DealerConnect > TechConnect > 14-Fuel System > Fuel Delivery, Gas > Module, Fuel Pump > Installation > Front Wheel Drive NOTE: Clock the Fuel Module to the 2:00 position Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-024-10 > Sep > 10 > Instruments - Fuel Gauge Fluctuation > Page 7489 5. Install the jumper hose kit 6. Re-Connect battery 7. Start vehicle and check for leaks 8. Re-install Fuel Pump Cover 9. Re-install padding and rear seat bottom 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module (AWD) Fuel Gauge Sender: Locations Fuel Pump Module (AWD) Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module (AWD) > Page 7492 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Pump Module (AWD) > Page 7493 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way Fuel Gauge Sender: Diagrams Fuel Pump Module (FWD) (Body) 4 Way Connector (FWD) - (BODY) 4 WAY MODULE-FUEL PUMP (FWD) - (BODY) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way > Page 7496 Fuel Gauge Sender: Diagrams Fuel Pump Module C1 (AWD) (Body) 5 Way Connector C1 (AWD) - (BODY) 5 WAY MODULE-FUEL PUMP (AWD) - (BODY) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Fuel Pump Module (FWD) (Body) 4 Way > Page 7497 Fuel Gauge Sender: Diagrams Fuel Pump Module C2 (AWD) (Body) 2 Way Connector C2 (AWD) - (BODY) 2 WAY MODULE-FUEL PUMP (AWD) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Gauge Sender: Description and Operation Fuel Pump Module - Description DESCRIPTION - FUEL PUMP MODULE The fuel pump module is located on the top left side of the fuel tank. The fuel pump module contains the following components: - Mounting flange - Electric fuel pump - Fuel pump reservoir - Inlet strainer - Fuel pressure regulator - Fuel level sending unit - Fuel filter The fuel level sending unit (3) is the only serviceable component of the fuel pump module. If the electric fuel pump, fuel pressure regulator or fuel filter requires service, the fuel pump module must be replaced as an assembly. DESCRIPTION The fuel pump module is installed in the top of the fuel tank. The fuel pump module contains the following: - Electric fuel pump - Fuel pump reservoir Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description > Page 7500 - Inlet strainer - Fuel pressure regulator - Fuel gauge sending unit - Fuel supply line connection - Fuel Filter NOTE: The fuel level sending unit is the only serviceable item. If the fuel pump, fuel pressure regulator or fuel filters need service, replace the fuel pump module as an assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump Module - Description > Page 7501 Fuel Gauge Sender: Description and Operation Fuel Pump Module - Operation OPERATION - FUEL PUMP MODULE An electric fuel pump is located within the fuel pump module. The electric fuel pump is a positive displacement, immersible pump with a permanent magnet electric motor capable of creating 860 kPa (125 psi) of operating pressure. The fuel pressure regulator limits fuel pressure to 400 kPa (58 psi). The fuel gauge is controlled by the instrument cluster circuit board based upon cluster programming and a hard wired input received by the cluster from the fuel level sending unit on the module in the fuel tank. The instrument cluster continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. This information is available to other vehicle control modules via the Controller Area Network (CAN) data bus. Fuel gauge diagnosis is conducted as part ofthe instrument cluster circuitry. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Gauge Sender: Service and Repair Fuel Pump Module - Removal REMOVAL WARNING: Risk of injury to eyes and skin from contact with fuel, Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Failure to comply may result in serious or fatal injury. 1. Perform Fuel System Pressure Release procedure. See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose. 3. Remove the negative battery cable. 4. Remove the rear seat cushion. 5. Rear seat cushion loose. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 7504 6. Remove plastic cover. 7. Clean top of tank to remove loose dirt and debris. 8. Use special tool #9340 to remove left side module lock ring. 9. Note the fuel pump location on the top of the fuel tank. NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 7505 10. Pull module up out of fuel tank, make sure that you do not spill fuel inside of vehicle. 11. Drain fuel from fuel pump module. Do not spill fuel in interior of vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 7506 Fuel Gauge Sender: Service and Repair Fuel Pump Module - Installation INSTALLATION NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly. 1. Wipe seal area of tank clean. Place a new seal between the tank threads and the pump module opening. 2. Install module. 3. Position fuel pump module in tank. Make sure the alignment tab lines up on the fuel tank and pump module for Gas or Diesel fuel tanks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 7507 4. While holding the pump module in position, install lock ring and use special tool Spanner Wrench #9340 to tighten lock ring. 5. Install plastic cover. 6. Install rear cushion. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 7508 7. Install the negative battery cable. 8. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. 9. Fill fuel tank with clean fuel. Use the Scan Tool to pressurize the system and check for leaks. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor - Description Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Description DESCRIPTION The ambient temperature sensor is a variable resistor type sensor. It is mounted in the lower radiator grille opening, below the bumper and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor - Description > Page 7513 Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the Totally Integrated Power Module (TIPM). Based upon the resistance in the sensor, the instrument cluster or Cab Compartment Node (CCN) display senses a specific voltage on the Controller Area Network (CAN) data bus circuit, which corresponds to a specific temperature. The compass/temperature display unit then displays the proper ambient temperature. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Page 7514 Outside Temperature Display Sensor: Testing and Inspection AMBIENT TEMPERATURE SENSOR The thermometer function is supported by the ambient temperature sensor, the Totally Integrated Power Module (TIPM), the Controller Area Network (CAN) data bus circuit, and the instrument cluster or Cab Compartment Node (CCN) compass/temperature display unit. NOTE: The system displays the last known temperature when starting the vehicle and may take some time/mileage to update to an accurate current reading, up to 5 minutes at a maintained speed above 40 mph (64.3 kph). Customers with very short commutes may not get an updated reading before the vehicle is turned off, or if the ignition does not remain in the OFF position for more than 255 minutes (4hrs. 15min.). This strategy was intended to eliminate wildly fluctuating readings and may cause some customer confusion leading to unnecessary diagnostics/parts replacements. If the display shows " _ _ _ ", there is an OPEN or SHORT CIRCUIT that must be repaired. The ambient temperature sensor can be diagnosed using the following Sensor Test. SENSOR TESTING 1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable. 2. Disconnect the ambient temperature sensor wire harness connector. 3. Measure the resistance of the ambient temperature sensor. At room temperature (approx. 20° C (68°F)), the sensor resistance should be between 9-11 Kilo Ohms (9000-11000 ohms). The sensor resistance should read between these two values. If OK, refer to the appropriate diagnostic information to continue diagnosis of the Totally Integrated Power Module (TIPM), the Controller Area Network (CAN) data bus circuit, and the instrument cluster or CCN. If not OK, replace the inoperative ambient temperature sensor. The most reliable, efficient and accurate means to diagnose the ambient temperature circuit requires the use of a scan tool and the proper diagnostic procedure information. Refer to wiring for the appropriate information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor Removal Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a suitable tool, release the push pin type retainer that secures the ambient temperature sensor to the lower left side of the front bumper. 3. Disconnect the wire harness connector (1) from the ambient temperature sensor (2). 4. Remove the ambient temperature sensor from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor Removal > Page 7517 Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor Installation INSTALLATION 1. Connect the wire harness connector (1) to the ambient temperature sensor (2). 2. Position the ambient temperature sensor in the vehicle. 3. Install the push pin type retainer that secures the ambient temperature sensor to the lower left side of the front bumper. 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 7521 Parking Brake Warning Switch: Diagrams Connector - (INSTRUMENT PANEL) 1 WAY SWITCH-PARKING BRAKE - (INSTRUMENT PANEL) 1 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 7527 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 7528 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Tire Pressure Monitor Receiver / Transponder: Diagrams Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT FRONT (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way > Page 7531 Tire Pressure Monitor Receiver / Transponder: Diagrams Left Rear Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT REAR (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way > Page 7532 Tire Pressure Monitor Receiver / Transponder: Diagrams Right Rear Tire Pressure Transponder (Tire Pressure Monitor) (Body) 6 Way Connector (TIRE PRESSURE MONITOR) - (BODY) 6 WAY TRANSPONDER-TIRE PRESSURE-RIGHT REAR (TIRE PRESSURE MONITOR) - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Description DESCRIPTION A transponder, sometimes referred to as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of a vehicle equipped with Premium TPM. These transponders are used to provide the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. On this vehicle, there is a transponder located in the left front, left rear, and right rear wheelhouse. There is not a transponder located in the right front wheelhouse. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description > Page 7535 Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Operation OPERATION On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (The auto-locating process will start again only if the vehicle has been shut off for approximately 20 minutes or longer). Once the WCM has performed this to the three locations that have transponders, it uses the process-of-elimination theory to figure out the location of the fourth sensor ID. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Removal Front FRONT 1. Remove the wheelhouse splash shield at the transponder requiring service. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 2. Disconnect the wiring harness connector (2) at the transponder (1). 3. Remove the mounting nuts (3), then remove the transponder (1). Rear REAR 1. Remove the wheelhouse splash shield at the transponder requiring service. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Removal 2. Disconnect the wiring harness connector (3) at the transponder (1). 3. Remove the mounting nuts (2), then remove the transponder (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 7538 Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Installation Front FRONT 1. Position the transponder (1) and install the mounting nuts (3). 2. Connect the wiring harness connector (2) to the transponder (1). 3. Install the wheelhouse splash shield and all components removed to access it. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test. Rear REAR 1. Position the transponder (1) and install the mounting nuts (2). 2. Connect the wiring harness connector (3) to the transponder (1). 3. Install the rear wheelhouse splash shield and all components removed to access it. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation 4. Perform the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The Tire Pressure Monitoring (TPM) system has been optimized for the original equipment tires and wheels. TPM system pressures have been established for the tire size equipped on the vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, or style. Aftermarket wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with TPM, as damage to the sensors may result. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and therefore do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing. CAUTION: When installing the valve core, be sure to tighten the core to specifications See: Maintenance/Wheels and Tires/Wheels/Specifications . Overtightening by a little as three or four inch pounds can damage the sensor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a white outline oval (black center) insignia (3) on the sensor body. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 7544 The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by either a solid white oval insignia (3) on the body or. . a solid white oval insignia (3) with 433 printed in the center. The sensors are identical except for the oval insignia. The 433 MHz sensors can either have a black or grey sensor body. CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Sensors may be identified by valve stem cap color. From the factory, 315 MHz sensors have a gray valve stem cap while 433 MHz sensors have a black valve stem cap. Otherwise, once mounted inside a tire and wheel assembly you are not able to visually tell the difference between a 315 MHz and 433 MHz sensor. At that point, the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing visual inspection of the sensor body. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 7545 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (2) and Metal Washer (1) - Valve Stem Cap (4) - Valve Stem Core - Valve Stem Nut (with pressed-in washer) (3) NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer (1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available. The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 7546 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit by using a special tool such as a TPM-RKE Analyzer, or from a transponderSee: Tire Pressure Monitor Receiver / Transponder/Description and Operation/Tire Pressure Monitoring (TPM) Transponder - Operation. The TPM-RKE Analyzer has the ability to change the sensor's operating mode to PARK MODE and to help diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following operating modes: - SLEEP MODE - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. - PARK MODE - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 psi (6.9 kPa) delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure. - 30 BLOCK MODE - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to PARK MODE using a TPM-RKE Analyzer, the sensor's operating mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15 mph (24 km/h). In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 10 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to DRIVE MODE. - DRIVE MODE - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). Anytime the vehicle speed drops below 15 mph (24 km/h), the sensor mode will still be in Drive Mode, but will not transmit until the vehicle reaches speeds over 15 mph (24 km/h) once again. If the vehicle has been stationary for more then 20 minutes, the sensor state will transition to Park Mode. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 mph (24 km/h)" after a sensor has been replaced. The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The WCM can also learn the sensor's ID using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed in the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 7549 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 7550 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 8 Nm (71 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 7551 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the outer and inner tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. 8. Remove the support and lower the vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 7552 b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Turbo Boost Gauge > Component Information > Service and Repair > Boost Gauge - Removal Turbo Boost Gauge: Service and Repair Boost Gauge - Removal REMOVAL 1. Open hood, disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, and potentially serious or fatal injury. 2. Remove the instrument panel end caps See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel End Cap - Removal. 3. Remove the knee blocker airbag (if equipped) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Knee Blocker Air Bag - Removal. 4. Remove the steering column opening cover See: Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 5. Remove the instrument panel center bezel See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 6. Remove the A-pillar trim, both right and left sides See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/A-Pillar Trim Panel-Removal. 7. Remove the instrument panel top cover See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Removal. 8. Loosen the instrument panel upper panel enough to lift the left side up to remove the boost gauge wiring and electrical connector.See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Pad - Removal. 9. Disconnect the one electrical connector (2) the boost gauge. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Turbo Boost Gauge > Component Information > Service and Repair > Boost Gauge - Removal > Page 7557 10. Pull the upper panel towards rear of vehicle just enough on the left side to release the two clips at the cluster. 11. From behind the upper panel, remove the two nuts (1) holding the boost gauge to the panel. 12. Slide the gauge out from the center of the bezel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Turbo Boost Gauge > Component Information > Service and Repair > Boost Gauge - Removal > Page 7558 Turbo Boost Gauge: Service and Repair Boost Gauge - Installation INSTALLATION 1. Slide the boost gauge into the bezel and upper panel and install the two nuts (1). 2. Connect the one electrical connector (2). 3. Install the screws that were taken out to allow the left side of the upper panel to be lifted up. See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Pad - Installation. 4. Install the instrument panel top cover See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Cover - Installation. 5. Install the A-pillar trim, both right and left sides See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Turbo Boost Gauge > Component Information > Service and Repair > Boost Gauge - Removal > Page 7559 Trim/A-Pillar Trim Panel-Installation. 6. Install the instrument panel center bezel See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 7. Install the steering column opening cover See: Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 8. Install the knee blocker airbag (if equipped) See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Knee Blocker Air Bag - Installation. 9. Install the instrument panel end caps See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel End Cap - Installation. WARNING: Do not connect the battery negative cable See: Restraint Systems/Testing and Inspection . Serious or fatal injury may result if the system test is not performed first. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams Backup Lamp Switch: Diagrams Connector (GAS 5 SPD MTX) - (BODY) 2 WAY SWITCH-BACKUP LAMP (GAS 5 SPD MTX) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > Backup Lamp Switch - Removal Backup Lamp Switch: Service and Repair Backup Lamp Switch - Removal REMOVAL 1. Lift vehicle on hoist. 2. From bottom side of vehicle, disconnect back-up lamp switch connector (2). 3. Unscrew switch (2) from transaxle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > Backup Lamp Switch - Removal > Page 7567 Backup Lamp Switch: Service and Repair Backup Lamp Switch - Installation INSTALLATION 1. Install back-up lamp switch (2). Teflon tape or equivalent must be used on switch threads. Tighten switch to 24 Nm (18 ft. lbs.). CAUTION: Do not overtighten switch. 2. Connect back-up lamp switch connector (2). 3. Lower vehicle. 4. Verify back-up lamp operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Locations > Left Tail/Stop Lamp Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Locations > Left Tail/Stop Lamp > Page 7572 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Locations > Left Tail/Stop Lamp > Page 7573 Brake Lamp: Locations Right Tail/Stop Lamp Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Locations > Left Tail/Stop Lamp > Page 7574 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Left Tail/Stop Lamp (Body) 3 Way Brake Lamp: Diagrams Left Tail/Stop Lamp (Body) 3 Way Connector - (BODY) 3 WAY LAMP-TAIL/STOP-LEFT - (BODY) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Left Tail/Stop Lamp (Body) 3 Way > Page 7577 Brake Lamp: Diagrams Left Tail/Stop Lamp (Trailer Tow) 3Way Connector - (TRAILER_TOW) 3WAY LAMP-TAIL/STOP-LEFT - (TRAILER_TOW) 3WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Left Tail/Stop Lamp (Body) 3 Way > Page 7578 Brake Lamp: Diagrams Right Tail/Stop Lamp (Body) 3 Way Connector - (BODY) 3 WAY LAMP-TAIL/STOP-RIGHT - (BODY) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Left Tail/Stop Lamp (Body) 3 Way > Page 7579 Brake Lamp: Diagrams Right Tail/Stop Lamp (Trailer Tow) 3 Way Connector - (TRAILER_TOW) 3 WAY LAMP-TAIL/STOP-RIGHT - (TRAILER_TOW) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7583 Brake Light Switch: Diagrams Connector - (BODY) 6 WAY SWITCH-STOP LAMP - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description Brake Light Switch: Description and Operation Stop Lamp Switch - Description DESCRIPTION The stop lamp switch (2) is located under the instrument panel at the brake pedal arm. This switch contains three internal switches controlling various functions of the vehicle, one of them controls operation of the vehicle's brake lamps. Other functions of the internal switches include speed control deactivation and brake sense for the ABS and the brake transmission shift interlock. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description > Page 7586 Brake Light Switch: Description and Operation Stop Lamp Switch - Operation OPERATION The stop lamp switch has three internal switches used for various functions. Among these are: - Brake lamp actuation - Speed control deactivation, and - Brake sense for ABS and brake transmission shift interlock When the brake pedal is in the released position, the plunger on the outside of the stop lamp switch is pushed inward by the brake pedal. In this position, the electrical contacts for one internal switch are open while the electrical contacts for other two internal switches are closed. When the brake pedal is pressed, the plunger on the outside of the stop lamp switch extends outward. This action closes the electrical contacts for the one internal switch and opens the contacts for the remaining two switches within the stop lamp switch. The internal switch which closes when the brake pedal is pressed completes the circuit to the brake lamps at the rear of the vehicle, thus allowing illumination of the brake lamps and the center-high-mounted stop lamp (CHMSL). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 7587 Brake Light Switch: Testing and Inspection STOP LAMP SWITCH NOTE: Before proceeding with this diagnostic test, verify the adjustment of the stop lamp switch to rule out misadjustment. See: Adjustments If the electrical circuit has been tested and the stop lamp switch is suspected of being faulty, it can be tested using the following method. 1. Remove the switch from the vehicle. See: Service and Repair/Stop Lamp Switch - Removal 2. With the switch in the released position (plunger extended), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as indicated in the figure. 3. Gently push the plunger on the stop lamp switch in until it stops. 4. With the switch in the depressed position (plunger pushed in), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as indicated in the figure. If you do not achieve the results as indicated in both figures, the switch is faulty and must be replaced. 5. Install the switch in the vehicle. See: Service and Repair/Stop Lamp Switch - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 7588 Brake Light Switch: Adjustments ADJUSTMENT 1. Depress and hold the brake pedal. 2. Remove the stop switch from its bracket. To do so, rotate the stop lamp switch in a counterclockwise direction approximately 30 degrees from its proper mounting position. Pull the switch rearward and remove it from it's mounting bracket. 3. Hold the stop lamp switch firmly in one hand. Using your other hand, pull outward on the plunger of the switch until it has ratcheted out to its fully extended position. 4. Mount the stop lamp switch into the bracket as follows: Depress the brake pedal as far down as possible. Install the switch in its bracket by aligning the index key on switch with the notch in the square mounting hole of the mounting bracket. Once the switch is fully seated, rotate the switch clockwise approximately 30 degrees to lock the switch into the bracket. CAUTION: Do not use excessive force when pulling back on the brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. 5. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. 6. Check for proper operation of the brake lamps and speed control. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal Brake Light Switch: Service and Repair Stop Lamp Switch - Removal REMOVAL 1. Depress and hold the brake pedal. 2. Remove the stop lamp switch (2) from it's bracket on the brake pedal assembly (6). To do so, rotate the stop lamp switch in a counterclockwise direction approximately 30 degrees from its proper mounting position. Pull the switch rearward and remove it from its mounting bracket. 3. Disconnect the wiring harness connector (1) from the switch. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal > Page 7591 Brake Light Switch: Service and Repair Stop Lamp Switch - Installation INSTALLATION NOTE: Prior to installing the stop lamp switch into its bracket, the plunger must be moved to its fully extended position using the procedure described in 1. 1. Hold the stop lamp switch firmly in one hand. Using your other hand, pull outward on the plunger of the switch until it has ratcheted out to its fully extended position. 2. Connect the wiring harness connector (1) to the stop lamp switch (2). 3. Mount the stop lamp switch into the bracket on the brake pedal assembly (6) as follows: Depress the brake pedal as far down as possible. Install the switch in its bracket by aligning the index key on switch with the notch in the square mounting hole of the mounting bracket. Once the switch is fully seated, rotate the switch clockwise approximately 30 degrees to lock the switch into the bracket. CAUTION: Do not use excessive force when pulling back on the brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. 4. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. 5. Check for proper operation of the brake lamps and speed control. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Bulb > Component Information > Service and Repair > Cargo Lamp Bulb - Removal Cargo Lamp Bulb: Service and Repair Cargo Lamp Bulb - Removal With Flashlight Feature BULB - WITH FLASHLIGHT FEATURE NOTE: There are two types of cargo lamps available in this vehicle; one with and one without a removable flashlight feature. 1. Disconnect and isolate the battery negative cable. 2. Remove the flashlight from the cargo lamp housing (2). 3. Pull downward on the straight edge of the lens (1) to unsnap it from the lamp housing, then disengage the curved edge of the lens from the housing. 4. Carefully unsnap the bulb (3) from the two bulb holders within the cargo lamp housing. Without Flashlight Feature BULB - WITHOUT FLASHLIGHT FEATURE NOTE: There are two types of cargo lamps available in this vehicle; one with and one without a removable flashlight feature. 1. Disconnect and isolate the battery negative cable. 2. Insert the tip of a small flat-bladed screwdriver into the notch on one side of the cargo lamp between the lens (4) and the lamp housing (1). 3. Gently pry the notched edge of the lens downward until it unsnaps from the housing. 4. Swing the notched end of the lens downward far enough to access the bulb (3). 5. Carefully unsnap the bulb from the two bulb holders within the cargo lamp housing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Bulb > Component Information > Service and Repair > Cargo Lamp Bulb - Removal > Page 7597 Cargo Lamp Bulb: Service and Repair Cargo Lamp Bulb - Installation With Flashlight Feature BULB - WITH FLASHLIGHT FEATURE CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: There are two types of cargo lamps available in this vehicle; one with and one without a removable flashlight feature. 1. Align the ends of the bulb (3) with the two bulb holders within the cargo lamp housing (2). 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Position the curved edge of the lens (1) into position against the housing, then press upward on the straight edge of the lens firmly and evenly until it snaps into the housing. 4. Reinstall the flashlight into the cargo lamp housing. 5. Reconnect the battery negative cable. Without Flashlight Feature BULB - WITHOUT FLASHLIGHT FEATURE CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: There are two types of cargo lamps available in this vehicle; one with and one without a removable flashlight feature. 1. Align the ends of the bulb (3) with the two bulb holders within the cargo lamp housing (1). 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Swing the notched end of the lens (4) up into position against the housing, then press upward on the lens firmly and evenly until it snaps into the Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Cargo Lamp Bulb > Component Information > Service and Repair > Cargo Lamp Bulb - Removal > Page 7598 housing. 4. Reconnect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Service and Repair > Center Mounted Brake Lamp - Removal Center Mounted Brake Lamp: Service and Repair Center Mounted Brake Lamp - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear spoiler See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Service and Repair/Liftgate - Removal 3. With spoiler on bench, remove the two screws to the CHMSL. 4. Remove CHMSL from spoiler. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Service and Repair > Center Mounted Brake Lamp - Removal > Page 7604 Center Mounted Brake Lamp: Service and Repair Center Mounted Brake Lamp - Installation INSTALLATION 1. Place CHMSL onto rear spoiler. 2. Install the two mounting screws to the CHMSL. 3. Install the rear spoiler See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Service and Repair/Liftgate - Installation. 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Reading Lamp Bulb - Removal Courtesy Lamp Bulb: Service and Repair Reading Lamp Bulb - Removal BULB 1. Insert a trim stick between the lamp bezel (4) and courtesy/reading lamp lens (3) on the left side of the courtesy/reading lamp at (1). 2. Carefully swing lamp lens (3) toward the right side of the vehicle so that the tab (2) on the lens can come out of the lamp unit (4). 3. Remove bulb (3) from lamp unit (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Reading Lamp Bulb - Removal > Page 7610 Courtesy Lamp Bulb: Service and Repair Reading Lamp Bulb - Installation BULB 1. Position bulb (3) in holder and firmly press into place. NOTE: When installing the lens (5), make sure that the tab on the lens (4) is inserted on the right side of the courtesy/reading lamp unit first. 2. Once the right side tab (2) is in the headliner, roll up the left side of the lens (3) until it snaps into place at (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Description and Operation > Daytime Running Lamps - Description Daytime Running Lamp: Description and Operation Daytime Running Lamps - Description DESCRIPTION Vehicles built for use in Canada, and also available as an option on vehicles for sale in the U.S., are equipped with a Daytime Running Lamp (DRL) system. All the exterior lighting messages come from Steering Control Module (SCM) or left multi-function switch on Local Interconnect Network (LIN) data bus and goes to the Cab Compartment Node (CCN), then the CCN sends out a Controller Area Network (CAN) data bus message to the Totally Integrated Power Module (TIPM) for each lighting function according to the request from left multi-function switch. Then the TIPM will turn ON/OFF the requested output. The DRL function is controlled by TIPM. Daytime running lamps are High beam lamps at lower intensity. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Description and Operation > Daytime Running Lamps - Description > Page 7615 Daytime Running Lamp: Description and Operation Daytime Running Lamps - Operation OPERATION The Canadian cluster provides steady illumination of the front turn signal when the ignition switch is in the ON position. The Daytime Running Lamp (DRL) function may be inhibited by activating the turn signals, the hazard flashers, the headlamp switch, or park brake. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Dome Lamp Bulb - Removal Dome Lamp Bulb: Service and Repair Dome Lamp Bulb - Removal BULB 1. On lower line vehicles, there will be two overhead lamps located at (1 and 2). (1) is the Cargo Lamp, and (2) is the Dome Lamp. 2. Insert a trim stick or equivalent between the lamp unit (3) and the lens (1) at this position (2). 3. Carefully remove the lamp lens (1). 4. Remove lamp from lamp unit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Dome Lamp Bulb - Removal > Page 7621 Dome Lamp Bulb: Service and Repair Dome Lamp Bulb - Installation BULB 1. Push lamp in lamp unit (3) and snap into place. 2. Position lens (1) on lamp unit (3) and snap into place. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Fog Lamp Bulb - Removal Fog/Driving Lamp Bulb: Service and Repair Fog Lamp Bulb - Removal BULB 1. Disconnect and isolate the battery negative cable. 2. Reach up through the lower fascia (3) cutout. 3. Disconnect the fog lamp connector (1). 4. Twist the bulb (2) counterclockwise to remove from lamp unit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Fog Lamp Bulb - Removal > Page 7627 Fog/Driving Lamp Bulb: Service and Repair Fog Lamp Bulb - Installation BULB 1. Reach up through the lower fascia (3) cutout. 2. Place bulb (2) into lamp unit and twist clockwise until stops, approximately 90 degrees. 3. Connect the fog lamp bulb electrical connector (1). 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Fog/Driving Lamp Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing and controls are attached to the Steering Column Control Module (SCCM) (1) by one retaining screw. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single integral interface connector connects the left multi-function switch directly to the SCCM (1). The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. - Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door, the rear flip-up glass, or the liftgate are opened. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7632 - Interior Lamps On - The left multi-function switch control ring provides detent switching to simultaneously illuminate all interior courtesy lamps. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. - Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is damaged or inoperative, the entire switch unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7633 Fog/Driving Lamp Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch then sends electronic switch status messages over the Local Interconnect Network (LIN) to the Cab Compartment Node (CCN) and then the CCN sends messages over the Controller Area Network (CAN) data bus to the Totally Integrated Power Module (TIPM) other electronic modules in the vehicle. For lighting and wiper function it sends the messages over the LIN bus to the CCN and the CCN puts them out on the CAN bus to the other modules. The left switch has the microprocessor for all communication to the TIPM. The SCCM is composed of a clockspring and left lighting switch and a right wiper switch. The TIPM, controls the lighting and wiper functions. The left multi-function switch can be diagnosed using LIN based diagnostic tools and methods. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp On position is also selected, and will automatically move the control knob to the front fog lamps Off position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp beams are selected when the left multi-function switch control stalk is pushed forward. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Each time the control stalk is actuated in this manner, the headlamp beams are toggled from the current selection to the opposite selection. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled rearward to a momentary position just short of the beam selection detent position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the previously selected beams will be restored when the control stalk is released. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps On position is also selected, and will automatically move the control knob to the rear fog lamp Off position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary "lane change" position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring, rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps defeat detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7634 CAN data bus to the other electronic modules in the vehicle. - Interior Lamps On - The interior lamps on feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps On detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Parade Mode - The parade or funeral mode is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the parade mode is requested when the left multi-function switch control sleeve is rotated to the parade mode detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Fog/Driving Lamp Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL NOTE: It is not necessary to remove the Steering Column Control Module (SCCM) from the steering column to replace the left multi-function switch (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag or steering column components. 2. Remove both the upper and lower shrouds from the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the one screw (2) that secures the left multi-function switch (3) on the right side of the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 7637 4. Pull the switch (2) straight away from the clockspring (1) far enough to access the electrical connector (3) to disconnect it. 5. Disconnect the instrument panel wiring harness from the back of the left multi-function switch. 6. Remove the switch (2) from the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 7638 Fog/Driving Lamp Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION 1. Position the left multi-function switch in the slot in the back of the clockspring (1) and connect the switch connector (3). 2. Connect the instrument panel wiring harness connector to the back of the left multi-function switch. 3. Align switch (3) with the clockspring (1) and slide toward steering column. 4. Install the screw (2) that secures the switch (3) to the clockspring (1). 5. Install the upper and lower shrouds onto the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation > Hazard Warning Switch - Description Hazard Warning Switch: Description and Operation Hazard Warning Switch - Description DESCRIPTION The hazard switch is located in the Accessory Switch Bank Module (ASBM) just below the heater a/c controls, in the instrument panel center stack. This switch is the control for the hazard warning lighting. The only visible component of the switch is the control push button that is located just to the left of the Passenger Airbag Disabled Light (PADL) indicator. On BUX models, the hazard switch is located to the left of the Headlamp Leveling Switch, in the ASBM. The hazard switch cannot be adjusted or repaired. If the switch is ineffective or damaged, the entire ASBM must be replaced See: Accessories and Optional Equipment/Integrated Accessory Switch Assembly/Service and Repair/Instrument Cluster Switch Pod - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Description and Operation > Hazard Warning Switch - Description > Page 7644 Hazard Warning Switch: Description and Operation Hazard Warning Switch - Operation OPERATION The hazard switch features a push-push type latching push button. When the push button is in its latched (lowered) position the switch contacts are open, and when the push button is in its unlatched (raised) position the switch contacts are closed. The hazard switch receives a ground on one terminal and provides a ground signal output to the Totally Integrated Power Module (TIPM) ) whenever the switch contacts are closed. The TIPM responds to this input by controlling a battery voltage output and the flash rate for each of the right and left turn signal lamps, then sends an electronic hazard switch status message over the Controller Area Network (CAN) data bus to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) to control the illumination and flash rate of the right and left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. The hazard switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Front Lamp Unit Bulb - Removal Headlamp Bulb: Service and Repair Front Lamp Unit Bulb - Removal BULBS NOTE: The headlamp bulb can be accessed from under the hood without the removal of the inner fender well. It will be necessary to remove the inner fender well to service the park/turn signal bulb that is located toward the outboard side of the head lamp unit. 1. Disconnect and isolate the battery negative cable. 2. Hoist vehicle. 3. Working in the appropriate wheel well, loosen up the front of the splash shield, but don't fully remove it. 4. Looking up through the front wheel well, locate the bulb (1) in which needs replacing. The headlamp bulb is the inboard bulb and the park/turn signal bulb is the outboard bulb. 5. Disconnect the bulb electrical connector (2 or 3). NOTE: EXPORT ONLY - If removing/replacing the headlamp bulb on export vehicles there is a rubber cover over the rear of the lamp housing that must be removed to access the bulb. Then a spring clip must be removed and the bulb pulled straight rearward. 6. Grasp the bulb (1), twist 1/4 turn counterclockwise and pull straight out of front lamp unit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Front Lamp Unit Bulb - Removal > Page 7650 Headlamp Bulb: Service and Repair Front Lamp Unit Bulb - Installation BULBS NOTE: The headlamp bulb can be accessed from under the hood without the removal of the inner fender well. It will be necessary to remove the inner fender well to service the park/turn signal bulb that is located toward the outboard side of the head lamp unit. 1. Reaching up through wheel well, install the headlamp or park/turn signal bulb (1) in the front lamp unit, locking it into place by twisting a 1/4 turn clockwise. NOTE: EXPORT ONLY - If installing/replacing the headlamp bulb on export vehicles push the bulb straight in unit and then install the spring clip. Install the rubber cover over the rear of the lamp housing, over the headlamp bulb. 2. Connect the bulb electrical connector (2 or 3). 3. Install the front of the splash shield (6) removed to gain access to the front lamp unit bulbs See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Splash Shield - Installation. 4. Lower vehicle from hoist. 5. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Headlamp Dimmer Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing and controls are attached to the Steering Column Control Module (SCCM) (1) by one retaining screw. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single integral interface connector connects the left multi-function switch directly to the SCCM (1). The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. - Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door, the rear flip-up glass, or the liftgate are opened. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7655 - Interior Lamps On - The left multi-function switch control ring provides detent switching to simultaneously illuminate all interior courtesy lamps. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. - Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is damaged or inoperative, the entire switch unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7656 Headlamp Dimmer Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch then sends electronic switch status messages over the Local Interconnect Network (LIN) to the Cab Compartment Node (CCN) and then the CCN sends messages over the Controller Area Network (CAN) data bus to the Totally Integrated Power Module (TIPM) other electronic modules in the vehicle. For lighting and wiper function it sends the messages over the LIN bus to the CCN and the CCN puts them out on the CAN bus to the other modules. The left switch has the microprocessor for all communication to the TIPM. The SCCM is composed of a clockspring and left lighting switch and a right wiper switch. The TIPM, controls the lighting and wiper functions. The left multi-function switch can be diagnosed using LIN based diagnostic tools and methods. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp On position is also selected, and will automatically move the control knob to the front fog lamps Off position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp beams are selected when the left multi-function switch control stalk is pushed forward. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Each time the control stalk is actuated in this manner, the headlamp beams are toggled from the current selection to the opposite selection. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled rearward to a momentary position just short of the beam selection detent position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the previously selected beams will be restored when the control stalk is released. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps On position is also selected, and will automatically move the control knob to the rear fog lamp Off position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary "lane change" position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring, rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps defeat detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7657 CAN data bus to the other electronic modules in the vehicle. - Interior Lamps On - The interior lamps on feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps On detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Parade Mode - The parade or funeral mode is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the parade mode is requested when the left multi-function switch control sleeve is rotated to the parade mode detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Headlamp Dimmer Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL NOTE: It is not necessary to remove the Steering Column Control Module (SCCM) from the steering column to replace the left multi-function switch (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag or steering column components. 2. Remove both the upper and lower shrouds from the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the one screw (2) that secures the left multi-function switch (3) on the right side of the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 7660 4. Pull the switch (2) straight away from the clockspring (1) far enough to access the electrical connector (3) to disconnect it. 5. Disconnect the instrument panel wiring harness from the back of the left multi-function switch. 6. Remove the switch (2) from the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 7661 Headlamp Dimmer Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION 1. Position the left multi-function switch in the slot in the back of the clockspring (1) and connect the switch connector (3). 2. Connect the instrument panel wiring harness connector to the back of the left multi-function switch. 3. Align switch (3) with the clockspring (1) and slide toward steering column. 4. Install the screw (2) that secures the switch (3) to the clockspring (1). 5. Install the upper and lower shrouds onto the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Headlamp Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing and controls are attached to the Steering Column Control Module (SCCM) (1) by one retaining screw. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single integral interface connector connects the left multi-function switch directly to the SCCM (1). The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. - Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door, the rear flip-up glass, or the liftgate are opened. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7666 - Interior Lamps On - The left multi-function switch control ring provides detent switching to simultaneously illuminate all interior courtesy lamps. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. - Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is damaged or inoperative, the entire switch unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7667 Headlamp Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch then sends electronic switch status messages over the Local Interconnect Network (LIN) to the Cab Compartment Node (CCN) and then the CCN sends messages over the Controller Area Network (CAN) data bus to the Totally Integrated Power Module (TIPM) other electronic modules in the vehicle. For lighting and wiper function it sends the messages over the LIN bus to the CCN and the CCN puts them out on the CAN bus to the other modules. The left switch has the microprocessor for all communication to the TIPM. The SCCM is composed of a clockspring and left lighting switch and a right wiper switch. The TIPM, controls the lighting and wiper functions. The left multi-function switch can be diagnosed using LIN based diagnostic tools and methods. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp On position is also selected, and will automatically move the control knob to the front fog lamps Off position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp beams are selected when the left multi-function switch control stalk is pushed forward. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Each time the control stalk is actuated in this manner, the headlamp beams are toggled from the current selection to the opposite selection. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled rearward to a momentary position just short of the beam selection detent position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the previously selected beams will be restored when the control stalk is released. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps On position is also selected, and will automatically move the control knob to the rear fog lamp Off position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary "lane change" position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring, rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps defeat detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7668 CAN data bus to the other electronic modules in the vehicle. - Interior Lamps On - The interior lamps on feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps On detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Parade Mode - The parade or funeral mode is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the parade mode is requested when the left multi-function switch control sleeve is rotated to the parade mode detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Headlamp Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL NOTE: It is not necessary to remove the Steering Column Control Module (SCCM) from the steering column to replace the left multi-function switch (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag or steering column components. 2. Remove both the upper and lower shrouds from the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the one screw (2) that secures the left multi-function switch (3) on the right side of the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 7671 4. Pull the switch (2) straight away from the clockspring (1) far enough to access the electrical connector (3) to disconnect it. 5. Disconnect the instrument panel wiring harness from the back of the left multi-function switch. 6. Remove the switch (2) from the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 7672 Headlamp Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION 1. Position the left multi-function switch in the slot in the back of the clockspring (1) and connect the switch connector (3). 2. Connect the instrument panel wiring harness connector to the back of the left multi-function switch. 3. Align switch (3) with the clockspring (1) and slide toward steering column. 4. Install the screw (2) that secures the switch (3) to the clockspring (1). 5. Install the upper and lower shrouds onto the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Service and Repair > Horn Relay - Removal Horn Relay: Service and Repair Horn Relay - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power Module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Service and Repair > Horn Relay - Removal > Page 7678 Horn Relay: Service and Repair Horn Relay - Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 7682 Horn Switch: Diagrams Connector - (STEERING WHEEL) 2 WAY SWITCH-HORN - (STEERING WHEEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation > Horn Switch - Description Horn Switch: Description and Operation Horn Switch - Description DESCRIPTION WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and cautions before servicing the horn switch. The horn switch is mounted inside the driver airbag. The horn switch has three contacts that are grounded when the driver airbag is depressed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation > Horn Switch - Description > Page 7685 Horn Switch: Description and Operation Horn Switch - Operation OPERATION When the Driver Airbag Cover is pressed, the horn switch makes contact to ground. The ground signal is carried to the horn relay and the horn sounds. The horn switch grounds to the airbag housing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair > Horn Switch - Removal Horn Switch: Service and Repair Horn Switch - Removal REMOVAL WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and cautions before servicing the horn switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Removal. 3. Disconnect the connector from the clockspring. 4. Remove the three mounting fasteners. 5. Remove the horn switch. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair > Horn Switch - Removal > Page 7688 Horn Switch: Service and Repair Horn Switch - Installation INSTALLATION 1. Install the horn switch. 2. Install the three mounting fasteners. 3. Connect the electrical connector to the clockspring. 4. Install the driver airbag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Installation 5. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Left Front Park/Turn Lamp (Engine Compartment) 3 Way Parking Lamp: Diagrams Left Front Park/Turn Lamp (Engine Compartment) 3 Way Connector (EXCEPT EXPORT) - (ENGINE COMPARTMENT) 3 WAY LAMP-PARK/TURN-LEFT FRONT (EXCEPT EXPORT) - (ENGINE COMPARTMENT) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Left Front Park/Turn Lamp (Engine Compartment) 3 Way > Page 7694 Parking Lamp: Diagrams Right Front Park/Turn Lamp (Engine Compartment) 3 Way Connector (EXCEPT EXPORT) - (ENGINE COMPARTMENT) 3 WAY LAMP-PARK/TURN-RIGHT FRONT (EXCEPT EXPORT) - (ENGINE COMPARTMENT) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Service and Repair > Horn Relay - Removal Horn Relay: Service and Repair Horn Relay - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cover from Totally Integrated Power Module (TIPM). 3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Service and Repair > Horn Relay - Removal > Page 7700 Horn Relay: Service and Repair Horn Relay - Installation INSTALLATION 1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position. 2. Install cover to TIPM. 3. Connect battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Backup Lamp Switch: Diagrams Connector (GAS 5 SPD MTX) - (BODY) 2 WAY SWITCH-BACKUP LAMP (GAS 5 SPD MTX) - (BODY) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Backup Lamp Switch - Removal Backup Lamp Switch: Service and Repair Backup Lamp Switch - Removal REMOVAL 1. Lift vehicle on hoist. 2. From bottom side of vehicle, disconnect back-up lamp switch connector (2). 3. Unscrew switch (2) from transaxle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Backup Lamp Switch - Removal > Page 7707 Backup Lamp Switch: Service and Repair Backup Lamp Switch - Installation INSTALLATION 1. Install back-up lamp switch (2). Teflon tape or equivalent must be used on switch threads. Tighten switch to 24 Nm (18 ft. lbs.). CAUTION: Do not overtighten switch. 2. Connect back-up lamp switch connector (2). 3. Lower vehicle. 4. Verify back-up lamp operation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7711 Brake Light Switch: Diagrams Connector - (BODY) 6 WAY SWITCH-STOP LAMP - (BODY) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description Brake Light Switch: Description and Operation Stop Lamp Switch - Description DESCRIPTION The stop lamp switch (2) is located under the instrument panel at the brake pedal arm. This switch contains three internal switches controlling various functions of the vehicle, one of them controls operation of the vehicle's brake lamps. Other functions of the internal switches include speed control deactivation and brake sense for the ABS and the brake transmission shift interlock. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description > Page 7714 Brake Light Switch: Description and Operation Stop Lamp Switch - Operation OPERATION The stop lamp switch has three internal switches used for various functions. Among these are: - Brake lamp actuation - Speed control deactivation, and - Brake sense for ABS and brake transmission shift interlock When the brake pedal is in the released position, the plunger on the outside of the stop lamp switch is pushed inward by the brake pedal. In this position, the electrical contacts for one internal switch are open while the electrical contacts for other two internal switches are closed. When the brake pedal is pressed, the plunger on the outside of the stop lamp switch extends outward. This action closes the electrical contacts for the one internal switch and opens the contacts for the remaining two switches within the stop lamp switch. The internal switch which closes when the brake pedal is pressed completes the circuit to the brake lamps at the rear of the vehicle, thus allowing illumination of the brake lamps and the center-high-mounted stop lamp (CHMSL). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 7715 Brake Light Switch: Testing and Inspection STOP LAMP SWITCH NOTE: Before proceeding with this diagnostic test, verify the adjustment of the stop lamp switch to rule out misadjustment. See: Adjustments If the electrical circuit has been tested and the stop lamp switch is suspected of being faulty, it can be tested using the following method. 1. Remove the switch from the vehicle. See: Service and Repair/Stop Lamp Switch - Removal 2. With the switch in the released position (plunger extended), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as indicated in the figure. 3. Gently push the plunger on the stop lamp switch in until it stops. 4. With the switch in the depressed position (plunger pushed in), use an ohmmeter to test each of the three internal switches as shown. You should achieve the results as indicated in the figure. If you do not achieve the results as indicated in both figures, the switch is faulty and must be replaced. 5. Install the switch in the vehicle. See: Service and Repair/Stop Lamp Switch - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 7716 Brake Light Switch: Adjustments ADJUSTMENT 1. Depress and hold the brake pedal. 2. Remove the stop switch from its bracket. To do so, rotate the stop lamp switch in a counterclockwise direction approximately 30 degrees from its proper mounting position. Pull the switch rearward and remove it from it's mounting bracket. 3. Hold the stop lamp switch firmly in one hand. Using your other hand, pull outward on the plunger of the switch until it has ratcheted out to its fully extended position. 4. Mount the stop lamp switch into the bracket as follows: Depress the brake pedal as far down as possible. Install the switch in its bracket by aligning the index key on switch with the notch in the square mounting hole of the mounting bracket. Once the switch is fully seated, rotate the switch clockwise approximately 30 degrees to lock the switch into the bracket. CAUTION: Do not use excessive force when pulling back on the brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. 5. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. 6. Check for proper operation of the brake lamps and speed control. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal Brake Light Switch: Service and Repair Stop Lamp Switch - Removal REMOVAL 1. Depress and hold the brake pedal. 2. Remove the stop lamp switch (2) from it's bracket on the brake pedal assembly (6). To do so, rotate the stop lamp switch in a counterclockwise direction approximately 30 degrees from its proper mounting position. Pull the switch rearward and remove it from its mounting bracket. 3. Disconnect the wiring harness connector (1) from the switch. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal > Page 7719 Brake Light Switch: Service and Repair Stop Lamp Switch - Installation INSTALLATION NOTE: Prior to installing the stop lamp switch into its bracket, the plunger must be moved to its fully extended position using the procedure described in 1. 1. Hold the stop lamp switch firmly in one hand. Using your other hand, pull outward on the plunger of the switch until it has ratcheted out to its fully extended position. 2. Connect the wiring harness connector (1) to the stop lamp switch (2). 3. Mount the stop lamp switch into the bracket on the brake pedal assembly (6) as follows: Depress the brake pedal as far down as possible. Install the switch in its bracket by aligning the index key on switch with the notch in the square mounting hole of the mounting bracket. Once the switch is fully seated, rotate the switch clockwise approximately 30 degrees to lock the switch into the bracket. CAUTION: Do not use excessive force when pulling back on the brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. 4. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. 5. Check for proper operation of the brake lamps and speed control. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Combination Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing and controls are attached to the Steering Column Control Module (SCCM) (1) by one retaining screw. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single integral interface connector connects the left multi-function switch directly to the SCCM (1). The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. - Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door, the rear flip-up glass, or the liftgate are opened. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7724 - Interior Lamps On - The left multi-function switch control ring provides detent switching to simultaneously illuminate all interior courtesy lamps. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. - Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is damaged or inoperative, the entire switch unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7725 Combination Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch then sends electronic switch status messages over the Local Interconnect Network (LIN) to the Cab Compartment Node (CCN) and then the CCN sends messages over the Controller Area Network (CAN) data bus to the Totally Integrated Power Module (TIPM) other electronic modules in the vehicle. For lighting and wiper function it sends the messages over the LIN bus to the CCN and the CCN puts them out on the CAN bus to the other modules. The left switch has the microprocessor for all communication to the TIPM. The SCCM is composed of a clockspring and left lighting switch and a right wiper switch. The TIPM, controls the lighting and wiper functions. The left multi-function switch can be diagnosed using LIN based diagnostic tools and methods. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp On position is also selected, and will automatically move the control knob to the front fog lamps Off position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp beams are selected when the left multi-function switch control stalk is pushed forward. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Each time the control stalk is actuated in this manner, the headlamp beams are toggled from the current selection to the opposite selection. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled rearward to a momentary position just short of the beam selection detent position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the previously selected beams will be restored when the control stalk is released. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps On position is also selected, and will automatically move the control knob to the rear fog lamp Off position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary "lane change" position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring, rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps defeat detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7726 CAN data bus to the other electronic modules in the vehicle. - Interior Lamps On - The interior lamps on feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps On detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Parade Mode - The parade or funeral mode is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the parade mode is requested when the left multi-function switch control sleeve is rotated to the parade mode detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Combination Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL NOTE: It is not necessary to remove the Steering Column Control Module (SCCM) from the steering column to replace the left multi-function switch (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag or steering column components. 2. Remove both the upper and lower shrouds from the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the one screw (2) that secures the left multi-function switch (3) on the right side of the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 7729 4. Pull the switch (2) straight away from the clockspring (1) far enough to access the electrical connector (3) to disconnect it. 5. Disconnect the instrument panel wiring harness from the back of the left multi-function switch. 6. Remove the switch (2) from the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 7730 Combination Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION 1. Position the left multi-function switch in the slot in the back of the clockspring (1) and connect the switch connector (3). 2. Connect the instrument panel wiring harness connector to the back of the left multi-function switch. 3. Align switch (3) with the clockspring (1) and slide toward steering column. 4. Install the screw (2) that secures the switch (3) to the clockspring (1). 5. Install the upper and lower shrouds onto the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Fog/Driving Lamp Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing and controls are attached to the Steering Column Control Module (SCCM) (1) by one retaining screw. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single integral interface connector connects the left multi-function switch directly to the SCCM (1). The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. - Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door, the rear flip-up glass, or the liftgate are opened. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7735 - Interior Lamps On - The left multi-function switch control ring provides detent switching to simultaneously illuminate all interior courtesy lamps. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. - Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is damaged or inoperative, the entire switch unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7736 Fog/Driving Lamp Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch then sends electronic switch status messages over the Local Interconnect Network (LIN) to the Cab Compartment Node (CCN) and then the CCN sends messages over the Controller Area Network (CAN) data bus to the Totally Integrated Power Module (TIPM) other electronic modules in the vehicle. For lighting and wiper function it sends the messages over the LIN bus to the CCN and the CCN puts them out on the CAN bus to the other modules. The left switch has the microprocessor for all communication to the TIPM. The SCCM is composed of a clockspring and left lighting switch and a right wiper switch. The TIPM, controls the lighting and wiper functions. The left multi-function switch can be diagnosed using LIN based diagnostic tools and methods. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp On position is also selected, and will automatically move the control knob to the front fog lamps Off position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp beams are selected when the left multi-function switch control stalk is pushed forward. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Each time the control stalk is actuated in this manner, the headlamp beams are toggled from the current selection to the opposite selection. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled rearward to a momentary position just short of the beam selection detent position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the previously selected beams will be restored when the control stalk is released. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps On position is also selected, and will automatically move the control knob to the rear fog lamp Off position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary "lane change" position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring, rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps defeat detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7737 CAN data bus to the other electronic modules in the vehicle. - Interior Lamps On - The interior lamps on feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps On detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Parade Mode - The parade or funeral mode is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the parade mode is requested when the left multi-function switch control sleeve is rotated to the parade mode detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Fog/Driving Lamp Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL NOTE: It is not necessary to remove the Steering Column Control Module (SCCM) from the steering column to replace the left multi-function switch (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag or steering column components. 2. Remove both the upper and lower shrouds from the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the one screw (2) that secures the left multi-function switch (3) on the right side of the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 7740 4. Pull the switch (2) straight away from the clockspring (1) far enough to access the electrical connector (3) to disconnect it. 5. Disconnect the instrument panel wiring harness from the back of the left multi-function switch. 6. Remove the switch (2) from the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 7741 Fog/Driving Lamp Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION 1. Position the left multi-function switch in the slot in the back of the clockspring (1) and connect the switch connector (3). 2. Connect the instrument panel wiring harness connector to the back of the left multi-function switch. 3. Align switch (3) with the clockspring (1) and slide toward steering column. 4. Install the screw (2) that secures the switch (3) to the clockspring (1). 5. Install the upper and lower shrouds onto the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Hazard Warning Switch - Description Hazard Warning Switch: Description and Operation Hazard Warning Switch - Description DESCRIPTION The hazard switch is located in the Accessory Switch Bank Module (ASBM) just below the heater a/c controls, in the instrument panel center stack. This switch is the control for the hazard warning lighting. The only visible component of the switch is the control push button that is located just to the left of the Passenger Airbag Disabled Light (PADL) indicator. On BUX models, the hazard switch is located to the left of the Headlamp Leveling Switch, in the ASBM. The hazard switch cannot be adjusted or repaired. If the switch is ineffective or damaged, the entire ASBM must be replaced See: Accessories and Optional Equipment/Integrated Accessory Switch Assembly/Service and Repair/Instrument Cluster Switch Pod - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Hazard Warning Switch - Description > Page 7746 Hazard Warning Switch: Description and Operation Hazard Warning Switch - Operation OPERATION The hazard switch features a push-push type latching push button. When the push button is in its latched (lowered) position the switch contacts are open, and when the push button is in its unlatched (raised) position the switch contacts are closed. The hazard switch receives a ground on one terminal and provides a ground signal output to the Totally Integrated Power Module (TIPM) ) whenever the switch contacts are closed. The TIPM responds to this input by controlling a battery voltage output and the flash rate for each of the right and left turn signal lamps, then sends an electronic hazard switch status message over the Controller Area Network (CAN) data bus to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) to control the illumination and flash rate of the right and left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. The hazard switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Headlamp Dimmer Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing and controls are attached to the Steering Column Control Module (SCCM) (1) by one retaining screw. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single integral interface connector connects the left multi-function switch directly to the SCCM (1). The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. - Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door, the rear flip-up glass, or the liftgate are opened. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7751 - Interior Lamps On - The left multi-function switch control ring provides detent switching to simultaneously illuminate all interior courtesy lamps. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. - Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is damaged or inoperative, the entire switch unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7752 Headlamp Dimmer Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch then sends electronic switch status messages over the Local Interconnect Network (LIN) to the Cab Compartment Node (CCN) and then the CCN sends messages over the Controller Area Network (CAN) data bus to the Totally Integrated Power Module (TIPM) other electronic modules in the vehicle. For lighting and wiper function it sends the messages over the LIN bus to the CCN and the CCN puts them out on the CAN bus to the other modules. The left switch has the microprocessor for all communication to the TIPM. The SCCM is composed of a clockspring and left lighting switch and a right wiper switch. The TIPM, controls the lighting and wiper functions. The left multi-function switch can be diagnosed using LIN based diagnostic tools and methods. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp On position is also selected, and will automatically move the control knob to the front fog lamps Off position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp beams are selected when the left multi-function switch control stalk is pushed forward. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Each time the control stalk is actuated in this manner, the headlamp beams are toggled from the current selection to the opposite selection. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled rearward to a momentary position just short of the beam selection detent position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the previously selected beams will be restored when the control stalk is released. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps On position is also selected, and will automatically move the control knob to the rear fog lamp Off position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary "lane change" position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring, rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps defeat detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7753 CAN data bus to the other electronic modules in the vehicle. - Interior Lamps On - The interior lamps on feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps On detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Parade Mode - The parade or funeral mode is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the parade mode is requested when the left multi-function switch control sleeve is rotated to the parade mode detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Headlamp Dimmer Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL NOTE: It is not necessary to remove the Steering Column Control Module (SCCM) from the steering column to replace the left multi-function switch (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag or steering column components. 2. Remove both the upper and lower shrouds from the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the one screw (2) that secures the left multi-function switch (3) on the right side of the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 7756 4. Pull the switch (2) straight away from the clockspring (1) far enough to access the electrical connector (3) to disconnect it. 5. Disconnect the instrument panel wiring harness from the back of the left multi-function switch. 6. Remove the switch (2) from the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 7757 Headlamp Dimmer Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION 1. Position the left multi-function switch in the slot in the back of the clockspring (1) and connect the switch connector (3). 2. Connect the instrument panel wiring harness connector to the back of the left multi-function switch. 3. Align switch (3) with the clockspring (1) and slide toward steering column. 4. Install the screw (2) that secures the switch (3) to the clockspring (1). 5. Install the upper and lower shrouds onto the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Headlamp Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing and controls are attached to the Steering Column Control Module (SCCM) (1) by one retaining screw. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single integral interface connector connects the left multi-function switch directly to the SCCM (1). The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. - Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door, the rear flip-up glass, or the liftgate are opened. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7762 - Interior Lamps On - The left multi-function switch control ring provides detent switching to simultaneously illuminate all interior courtesy lamps. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. - Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is damaged or inoperative, the entire switch unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7763 Headlamp Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch then sends electronic switch status messages over the Local Interconnect Network (LIN) to the Cab Compartment Node (CCN) and then the CCN sends messages over the Controller Area Network (CAN) data bus to the Totally Integrated Power Module (TIPM) other electronic modules in the vehicle. For lighting and wiper function it sends the messages over the LIN bus to the CCN and the CCN puts them out on the CAN bus to the other modules. The left switch has the microprocessor for all communication to the TIPM. The SCCM is composed of a clockspring and left lighting switch and a right wiper switch. The TIPM, controls the lighting and wiper functions. The left multi-function switch can be diagnosed using LIN based diagnostic tools and methods. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp On position is also selected, and will automatically move the control knob to the front fog lamps Off position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp beams are selected when the left multi-function switch control stalk is pushed forward. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Each time the control stalk is actuated in this manner, the headlamp beams are toggled from the current selection to the opposite selection. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled rearward to a momentary position just short of the beam selection detent position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the previously selected beams will be restored when the control stalk is released. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps On position is also selected, and will automatically move the control knob to the rear fog lamp Off position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary "lane change" position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring, rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps defeat detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7764 CAN data bus to the other electronic modules in the vehicle. - Interior Lamps On - The interior lamps on feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps On detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Parade Mode - The parade or funeral mode is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the parade mode is requested when the left multi-function switch control sleeve is rotated to the parade mode detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Headlamp Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL NOTE: It is not necessary to remove the Steering Column Control Module (SCCM) from the steering column to replace the left multi-function switch (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag or steering column components. 2. Remove both the upper and lower shrouds from the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the one screw (2) that secures the left multi-function switch (3) on the right side of the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 7767 4. Pull the switch (2) straight away from the clockspring (1) far enough to access the electrical connector (3) to disconnect it. 5. Disconnect the instrument panel wiring harness from the back of the left multi-function switch. 6. Remove the switch (2) from the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 7768 Headlamp Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION 1. Position the left multi-function switch in the slot in the back of the clockspring (1) and connect the switch connector (3). 2. Connect the instrument panel wiring harness connector to the back of the left multi-function switch. 3. Align switch (3) with the clockspring (1) and slide toward steering column. 4. Install the screw (2) that secures the switch (3) to the clockspring (1). 5. Install the upper and lower shrouds onto the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 7772 Horn Switch: Diagrams Connector - (STEERING WHEEL) 2 WAY SWITCH-HORN - (STEERING WHEEL) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Horn Switch - Description Horn Switch: Description and Operation Horn Switch - Description DESCRIPTION WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and cautions before servicing the horn switch. The horn switch is mounted inside the driver airbag. The horn switch has three contacts that are grounded when the driver airbag is depressed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Description and Operation > Horn Switch - Description > Page 7775 Horn Switch: Description and Operation Horn Switch - Operation OPERATION When the Driver Airbag Cover is pressed, the horn switch makes contact to ground. The ground signal is carried to the horn relay and the horn sounds. The horn switch grounds to the airbag housing. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Horn Switch - Removal Horn Switch: Service and Repair Horn Switch - Removal REMOVAL WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and cautions before servicing the horn switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Removal. 3. Disconnect the connector from the clockspring. 4. Remove the three mounting fasteners. 5. Remove the horn switch. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Horn Switch - Removal > Page 7778 Horn Switch: Service and Repair Horn Switch - Installation INSTALLATION 1. Install the horn switch. 2. Install the three mounting fasteners. 3. Connect the electrical connector to the clockspring. 4. Install the driver airbag. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag Installation 5. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Tail Lamp Bulb - Removal Tail Light Bulb: Service and Repair Tail Lamp Bulb - Removal BULBS There are a total of four possible bulbs in the tail lamp unit: - Back-Up Lamp (4) - Park/Brake Lamp (1) - Rear Fog Lamp (5) - Export Only - Turn Signal (3) 1. Remove the tail lamp unit . See: Service and Repair/Tail Lamp - Removal NOTE: It is not necessary to completely remove the tail lamp unit. Once loosened from quarter panel, there should be enough room to service any of the bulbs. 2. Disconnect the electrical connector. 3. Remove bulb socket from tail lamp unit by twisting a quarter turn counterclockwise. 4. Pull socket straight out of tail lamp unit. 5. Pull bulb from socket. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Tail Lamp Bulb - Removal > Page 7784 Tail Light Bulb: Service and Repair Tail Lamp Bulb - Installation BULBS There are a total of four possible bulbs in the tail lamp unit: - Back-Up Lamp (4) - Park/Brake Lamp (1) - Rear Fog Lamp (5) - Export Only - Turn Signal (3) 1. Push bulb into the bulb socket. 2. Install bulb socket into tail lamp assembly. Rotate the socket clockwise until fully seated. 3. Install the tail lamp unit . See: Service and Repair/Tail Lamp Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description Combination Switch: Description and Operation Left Multifunction Switch - Description DESCRIPTION The left (lighting) multi-function switch is located on the left side of the steering column, just below the steering wheel. This switch is the primary control for the interior and exterior lighting systems. The only visible components of the switch are the control stalk (2), control knob (1) and control sleeve (3) that extend through the steering column shrouds on the left side of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator are concealed beneath the shrouds. The switch housing and controls are attached to the Steering Column Control Module (SCCM) (1) by one retaining screw. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single integral interface connector connects the left multi-function switch directly to the SCCM (1). The left multi-function switch provides the vehicle operator with a control interface for the following exterior lighting functions: - Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional front fog lamps. - Headlamps - The left multi-function switch control knob provides detent switching for the headlamps. - Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. - Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as an optical signalling device. - Park Lamps - The left multi-function switch control knob provides detent switching for the park lamps. - Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles manufactured for certain markets, where they are required. - Turn Signal Control - The left multi-function switch control stalk provides both momentary non-detent switching and detent switching with automatic cancellation for both the left and right turn signal lamps. The left multi-function switch also provides the vehicle operator with a control interface for the following interior lighting functions: - Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to defeat the illumination of all interior courtesy lamps when a door, the rear flip-up glass, or the liftgate are opened. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7790 - Interior Lamps On - The left multi-function switch control ring provides detent switching to simultaneously illuminate all interior courtesy lamps. - Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous adjustable control of the illumination intensity of all instrument panel lighting at one of six available illumination intensity levels. - Parade Mode - The left multi-function switch control ring provides detent switching for a parade mode that maximizes the illumination intensity of all instrument panel lighting for visibility when driving in daylight with the exterior lamps turned on. The left multi-function switch cannot be adjusted or repaired. If any function of the switch is damaged or inoperative, the entire switch unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7791 Combination Switch: Description and Operation Left Multifunction Switch - Operation OPERATION The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and features it provides using a minimal number of hard wired circuits. The switch then sends electronic switch status messages over the Local Interconnect Network (LIN) to the Cab Compartment Node (CCN) and then the CCN sends messages over the Controller Area Network (CAN) data bus to the Totally Integrated Power Module (TIPM) other electronic modules in the vehicle. For lighting and wiper function it sends the messages over the LIN bus to the CCN and the CCN puts them out on the CAN bus to the other modules. The left switch has the microprocessor for all communication to the TIPM. The SCCM is composed of a clockspring and left lighting switch and a right wiper switch. The TIPM, controls the lighting and wiper functions. The left multi-function switch can be diagnosed using LIN based diagnostic tools and methods. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. EXTERIOR LIGHTING Following are descriptions of how the left multi-function switch is operated to control the many exterior lighting functions and features it provides: - Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps to be selected while the headlamp On position is also selected, and will automatically move the control knob to the front fog lamps Off position when the control knob is rotated to deselect the headlamps. - Headlamps - The headlamps are requested when the left multi-function switch control knob is rotated to the headlamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Headlamp Beam Selection - The headlamp beams are selected when the left multi-function switch control stalk is pushed forward. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Each time the control stalk is actuated in this manner, the headlamp beams are toggled from the current selection to the opposite selection. - Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function switch control stalk is pulled rearward to a momentary position just short of the beam selection detent position. The headlamp high beams will remain illuminated for as long as the control stalk is held in this momentary position and the previously selected beams will be restored when the control stalk is released. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Park Lamps - The headlamps are requested when the left multi-function switch control knob is rotated to the park lamps on detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog lamps detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. The switch control knob incorporates an internal cam mechanism that will only allow the rear fog lamps to be selected while the front fog lamps On position is also selected, and will automatically move the control knob to the rear fog lamp Off position when the control knob is pushed in to deselect the front fog lamps. - Turn Signal Control - The turn signals are requested when the left multi-function switch control stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary "lane change" position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, a cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring, rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the left multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. INTERIOR LIGHTING Following are descriptions of the how the left multi-function switch is operated to control the many interior lighting functions and features it provides: - Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps defeat detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Left Multifunction Switch - Description > Page 7792 CAN data bus to the other electronic modules in the vehicle. - Interior Lamps On - The interior lamps on feature is requested when the left multi-function switch control sleeve is rotated to the interior lamps On detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Panel Lamps Dimming - The panel lamps dimming function is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the panel lamps dimming level is requested when the left multi-function switch control sleeve is rotated to any one of five minor detent positions. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. - Parade Mode - The parade or funeral mode is active only when the left multi-function switch control knob is in any exterior lighting On position. With the exterior lighting On, the parade mode is requested when the left multi-function switch control sleeve is rotated to the parade mode detent position. The left multi-function switch sends an electronic switch status message over the LIN bus to the CCN, then over the CAN data bus to the other electronic modules in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal Combination Switch: Service and Repair Left Multifunction Switch - Removal REMOVAL NOTE: It is not necessary to remove the Steering Column Control Module (SCCM) from the steering column to replace the left multi-function switch (2). 1. Disconnect and isolate the battery negative cable. WARNING: Wait two minutes for the system reserve capacitor to discharge before servicing any airbag or steering column components. 2. Remove both the upper and lower shrouds from the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the one screw (2) that secures the left multi-function switch (3) on the right side of the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 7795 4. Pull the switch (2) straight away from the clockspring (1) far enough to access the electrical connector (3) to disconnect it. 5. Disconnect the instrument panel wiring harness from the back of the left multi-function switch. 6. Remove the switch (2) from the clockspring (1). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Left Multifunction Switch - Removal > Page 7796 Combination Switch: Service and Repair Left Multifunction Switch - Installation INSTALLATION 1. Position the left multi-function switch in the slot in the back of the clockspring (1) and connect the switch connector (3). 2. Connect the instrument panel wiring harness connector to the back of the left multi-function switch. 3. Align switch (3) with the clockspring (1) and slide toward steering column. 4. Install the screw (2) that secures the switch (3) to the clockspring (1). 5. Install the upper and lower shrouds onto the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 6. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Locations > Front Park/Turn Lamp Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Locations > Front Park/Turn Lamp > Page 7801 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Locations > Front Park/Turn Lamp > Page 7802 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Locations > Front Park/Turn Lamp > Page 7803 Turn Signal Lamp: Locations Right Tail/Turn Lamp Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Locations > Front Park/Turn Lamp > Page 7804 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Left Front Park/Turn Lamp (Engine Compartment) 3 Way Turn Signal Lamp: Diagrams Left Front Park/Turn Lamp (Engine Compartment) 3 Way Connector (EXCEPT EXPORT) - (ENGINE COMPARTMENT) 3 WAY LAMP-PARK/TURN-LEFT FRONT (EXCEPT EXPORT) - (ENGINE COMPARTMENT) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Left Front Park/Turn Lamp (Engine Compartment) 3 Way > Page 7807 Turn Signal Lamp: Diagrams Left Tail/Turn Lamp (Body Or Trailer Tow) 3 Way Connector - (BODY OR TRAILER TOW) 3 WAY LAMP-TAIL TURN-LEFT - (BODY OR TRAILER TOW) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Left Front Park/Turn Lamp (Engine Compartment) 3 Way > Page 7808 Turn Signal Lamp: Diagrams Right Front Park/Turn Lamp (Engine Compartment) 3 Way Connector (EXCEPT EXPORT) - (ENGINE COMPARTMENT) 3 WAY LAMP-PARK/TURN-RIGHT FRONT (EXCEPT EXPORT) - (ENGINE COMPARTMENT) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Left Front Park/Turn Lamp (Engine Compartment) 3 Way > Page 7809 Turn Signal Lamp: Diagrams Right Tail/Turn Lamp (Body Or Trailer Tow) 3 Way Connector - (BODY OR TRAILER TOW) 3 WAY LAMP-TAIL TURN-RIGHT - (BODY OR TRAILER TOW) 3 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Description DESCRIPTION The switch for the rear window defogger (EBL) system (2) is located in the A/C-heater control (1) in the instrument panel center bezel. When the rear window defogger switch is pressed to the On position a request signal is sent to the cabin compartment node (CCN), which sends a message to the totally integrated power module (TIPM) to operate the EBL system. When the high side driver in the TIPM is energized, current is directed to the rear defogger grid lines and to the heated side view mirrors (when equipped) to help clear the glass surfaces of fog or frost. An amber indicator (3) in the rear window defogger switch will illuminate when the EBL system is turned on. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description > Page 7816 Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Operation OPERATION An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the cabin compartment node (CCN), which sends a message to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors, when equipped. NOTE: The EBL system turns off automatically after 10 minutes of initial operation. Each following activation cycle of the EBL system will last 5 minutes. The EBL system will automatically turn off after an initial programmed time interval of about 10 minutes as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 5 minutes. The EBL system will also turn off if the ignition switch is turned to any position other than RUN or by manually pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool. The rear window defogger switch and indicator cannot be adjusted or repaired. The A/C-heater control must be replaced if the rear window defogger switch or indicator is found inoperative or damaged See: Heating and Air Conditioning/Control Assembly/Service and Repair/A/C and Heater Control - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Description DESCRIPTION The switch for the rear window defogger (EBL) system (2) is located in the A/C-heater control (1) in the instrument panel center bezel. When the rear window defogger switch is pressed to the On position a request signal is sent to the cabin compartment node (CCN), which sends a message to the totally integrated power module (TIPM) to operate the EBL system. When the high side driver in the TIPM is energized, current is directed to the rear defogger grid lines and to the heated side view mirrors (when equipped) to help clear the glass surfaces of fog or frost. An amber indicator (3) in the rear window defogger switch will illuminate when the EBL system is turned on. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description > Page 7822 Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Operation OPERATION An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the cabin compartment node (CCN), which sends a message to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors, when equipped. NOTE: The EBL system turns off automatically after 10 minutes of initial operation. Each following activation cycle of the EBL system will last 5 minutes. The EBL system will automatically turn off after an initial programmed time interval of about 10 minutes as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 5 minutes. The EBL system will also turn off if the ignition switch is turned to any position other than RUN or by manually pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool. The rear window defogger switch and indicator cannot be adjusted or repaired. The A/C-heater control must be replaced if the rear window defogger switch or indicator is found inoperative or damaged See: Heating and Air Conditioning/Control Assembly/Service and Repair/A/C and Heater Control - Removal. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Front Power Window Switch Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Front Power Window Switch > Page 7827 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver Power Window Switch C1 (Left/Right Front Door) 6 Way Power Window Switch: Diagrams Driver Power Window Switch C1 (Left/Right Front Door) 6 Way Connector C1 - (LEFT/RIGHT FRONT DOOR) 6 WAY SWITCH-POWER WINDOW-DRIVER - (LEFT/RIGHT FRONT DOOR) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver Power Window Switch C1 (Left/Right Front Door) 6 Way > Page 7830 Power Window Switch: Diagrams Left Rear Power Window Switch (Left Rear Door) 6 Way Connector - (LEFT REAR DOOR) 6 WAY SWITCH-POWER WINDOW-LEFT REAR - (LEFT REAR DOOR) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver Power Window Switch C1 (Left/Right Front Door) 6 Way > Page 7831 Power Window Switch: Diagrams Passenger Power Window Switch (Left/Right Front Door) 6 Way Connector - (LEFT/RIGHT FRONT DOOR) 6 WAY SWITCH-POWER WINDOW-PASSENGER - (LEFT/RIGHT FRONT DOOR) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver Power Window Switch C1 (Left/Right Front Door) 6 Way > Page 7832 Power Window Switch: Diagrams Right Rear Power Window Switch (Right Rear Door) 6 Way Connector - (RIGHT REAR DOOR) 6 WAY SWITCH-POWER WINDOW-RIGHT REAR - (RIGHT REAR DOOR) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal Power Window Switch: Service and Repair Power Window Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Removal. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal > Page 7835 Power Window Switch: Service and Repair Power Window Switch - Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Installation 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Window Regulator Motor - Removal Front Door Window Motor: Service and Repair Window Regulator Motor - Removal REMOVAL 1. Move the window to the full UP position, if possible. 2. Disconnect and isolate the battery negative cable. 3. Remove the front door module. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Removal. 4. Disconnect electrical harness connector from motor. 5. Remove window regulator. 6. With regulator on bench, remove four screws retaining the motor to the regulator and remove motor. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Window Regulator Motor - Removal > Page 7842 Front Door Window Motor: Service and Repair Window Regulator Motor - Installation INSTALLATION 1. With regulator on bench, install four screws retaining the motor to the regulator. 2. Install the window regulator. 3. Connect the electrical harness connector to window motor. 4. Install the door module See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Installation. 5. Connect battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Front Power Window Switch Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Front Power Window Switch > Page 7847 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Driver Power Window Switch C1 (Left/Right Front Door) 6 Way Power Window Switch: Diagrams Driver Power Window Switch C1 (Left/Right Front Door) 6 Way Connector C1 - (LEFT/RIGHT FRONT DOOR) 6 WAY SWITCH-POWER WINDOW-DRIVER - (LEFT/RIGHT FRONT DOOR) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Driver Power Window Switch C1 (Left/Right Front Door) 6 Way > Page 7850 Power Window Switch: Diagrams Left Rear Power Window Switch (Left Rear Door) 6 Way Connector - (LEFT REAR DOOR) 6 WAY SWITCH-POWER WINDOW-LEFT REAR - (LEFT REAR DOOR) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Driver Power Window Switch C1 (Left/Right Front Door) 6 Way > Page 7851 Power Window Switch: Diagrams Passenger Power Window Switch (Left/Right Front Door) 6 Way Connector - (LEFT/RIGHT FRONT DOOR) 6 WAY SWITCH-POWER WINDOW-PASSENGER - (LEFT/RIGHT FRONT DOOR) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Driver Power Window Switch C1 (Left/Right Front Door) 6 Way > Page 7852 Power Window Switch: Diagrams Right Rear Power Window Switch (Right Rear Door) 6 Way Connector - (RIGHT REAR DOOR) 6 WAY SWITCH-POWER WINDOW-RIGHT REAR - (RIGHT REAR DOOR) 6 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal Power Window Switch: Service and Repair Power Window Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door bolster. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Removal. 3. Disconnect the electrical harness connectors. 4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the front of the cover and remove. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal > Page 7855 Power Window Switch: Service and Repair Power Window Switch - Installation INSTALLATION 1. Place the mirror switch in bolster opening and firmly snap into place. 2. Connect the electrical harness connectors. 3. Install the front door bolster. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Installation 4. Connect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Front Door Glass - Removal Front Door Window Glass: Service and Repair Front Door Glass - Removal REMOVAL 1. Remove bolster.See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Removal 2. Move glass to line up snap plates with access holes (1). 3. Using a punch or equivalent, press tabs releasing glass from window regulator. 4. Manually move glass upward to full up position and remove from window frame. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Service and Repair > Front Door Glass - Removal > Page 7861 Front Door Window Glass: Service and Repair Front Door Glass - Installation INSTALLATION 1. Insert glass into glass channel and slide down ensuring access holes (1) align with snaps. 2. Ensure access holes properly lock into snaps (1). 3. Install bolster. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Bolster - Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Quarter Glass - Removal Quarter Window Glass: Service and Repair Quarter Glass - Removal REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions See: Service Precautions. 2. Remove the quarter panel trim from the side of the vehicle being serviced See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. CAUTION: Be careful not to damage painted surfaces when removing moldings or cutting urethane around the windshield. 3. Using razor knife, cut the urethane adhesive that secures the quarter glass (1) to window fence (2). 4. Carefully push the quarter window glass from the opening. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Quarter Glass - Removal > Page 7866 Quarter Window Glass: Service and Repair Quarter Glass - Installation INSTALLATION NOTE: Grand Cherokee shown, Caliber similar. WARNING: Do not operate the vehicle within 24 hours of quarter glass installation. It takes at least 24 hours for urethane adhesive to cure. If it is not cured, the quarter glass may not perform properly if the vehicle is in an accident. CAUTION: To help prevent water leaks, partially roll down the left and right door glass before installing the quarter glass. This avoids pressurizing the passenger compartment if a door is slammed before the urethane is cured. CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers. NOTE: To prevent corrosion, do not damage paint on the quarter glass fence when removing original urethane. NOTE: The quarter glass fence should be cleaned of most of its old urethane adhesive. A small amount of old urethane, approximately 1 mm (.04 in.) in height should remain on the fence. Do not completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. 1. Using a razor knife, level the original bead of urethane on the fence to a thickness of approximately 1 mm (0.04 in.). 2. If the quarter glass is being reused, remove as much of the original urethane as possible from the glass surface using a razor knife. WARNING: Do not use solvent based glass cleaners to clean the quarter glass before applying glass prep and primer or poor glass adhesion may result. 3. Clean the inside of the quarter glass with an ammonia based glass cleaner and a lint-free cloth. 4. Apply glass prep adhesion promoter 25 mm (1 in.) wide around the perimeter of the glass and 5 mm (0.2 in.) from the edge of the glass and wipe dry with a clean lint-free cloth until no streaks are visible. 5. Apply glass primer 25 mm (1 in.) wide around the perimeter of the glass and 5 mm (0.2 in.) from the edge of the glass. Allow at least three minutes drying time. 6. Using a flashlight, verify that the primer is completely and evenly installed along the perimeter of the quarter glass. 7. Re-prime any area that is not fully and evenly primed. 8. Clean the quarter glass fence with an ammonia based glass cleaner and a lint-free cloth. 9. Apply pinch weld primer 15 mm (0.75 in.) wide around the quarter glass fence. Allow at least three minutes drying time. 10. Using a flashlight, verify that the primer is completely and evenly installed along the quarter glass fence. 11. Re-prime any area that is not fully and evenly primed. CAUTION: Always apply the bead of adhesive to the quarter glass. Always install the quarter glass within 5 minutes after applying the adhesive. NOTE: If the original urethane adhesive has been exposed for more than 12 hours, the entire adhesive area will need to be re-primed prior to installing new adhesive. 12. Apply approximately a 10 mm (0.4 in.) wide bead of adhesive with a triangular nozzle approximately 6 mm (0.230 in.) from the edge of the glass starting at the bottom center of the quarter glass. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Quarter Glass - Removal > Page 7867 13. Run the end of the adhesive bead on the quarter glass parallel to the start of the bead and smooth the ends flush. 14. Place the quarter glass (1) into the window opening (2) and insert mounting studs through the holes in the window fence. 15. Install the headliner. 16. Install the quarter panel trim See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Rear Door Glass - Removal Rear Door Window Glass: Service and Repair Rear Door Glass - Removal REMOVAL 1. Remove speaker and grille.See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Speaker Removal 2. Remove bolster.See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel Bolster - Removal 3. Remove door module.See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door - Removal 4. Raise window (5) gaining access to window tabs. 5. With a punch or equivalent, press regulator tabs holding window in regulator (3). 6. Carefully, remove window (5). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Rear Door Glass - Removal > Page 7872 Rear Door Window Glass: Service and Repair Rear Door Glass - Installation INSTALLATION 1. Install window regulator to door panel. See: Window Regulator/Rear Door Window Regulator/Service and Repair/Rear Door Window Regulator Installation 2. Install glass (1) down through window channel into window regulator (2) ensuring glass properly seats in access holes. 3. Connect wire connectors. 4. Install door module.See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door - Installation 5. Install bolster.See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel Bolster - Installation 6. Install speaker and grille.See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Speaker Removal Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal Front Door Window Regulator: Service and Repair Front Door Window Regulator - Removal REMOVAL 1. Remove the carrier plate (1). See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door Carrier Plate Removal 2. Remove the motor or manual lift mechanism screws (2). 3. Remove the lower regulator screws (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal > Page 7878 4. Disconnect the regulator motor (1) electrical connector (7), if equipped. 5. Separate the regulator runners (5) from the support brackets (6) and remove the regulator assembly. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal > Page 7879 Front Door Window Regulator: Service and Repair Front Door Window Regulator - Installation INSTALLATION 1. Position the regulator assembly onto the door trim panel and seat the runner support clips (6) fully. 2. Connect the regulator motor (1) electrical connector (7). 3. Install the lower regulator screws (2) but do not tighten them at this time. 4. Install the motor or manual lift mechanism screws (2). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal > Page 7880 5. Install the carrier plate (1). See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Service and Repair/Front Door Carrier Plate Installation Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Removal Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Removal REMOVAL 1. Remove door module.See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door Carrier Plate - Removal. 2. Remove door glass (5).See: Window Glass/Rear Door Window Glass/Service and Repair/Rear Door Glass - Installation 3. Remove fasteners, wire connectors and remove window regulator (1) from door panel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Removal > Page 7885 Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Installation INSTALLATION 1. Fasten window regulator to door panel. 2. Connect wire connectors. 3. Install glass ensuring proper seat. See: Window Glass/Rear Door Window Glass/Service and Repair/Rear Door Glass Installation 4. Install door module. See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door Carrier Plate - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Rear Door Glass Channel - Removal Window Track: Service and Repair Rear Door Glass Channel - Removal REMOVAL 1. Remove door module. See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door Carrier Plate - Removal. 2. Remove glass run fastener (2). 3. Remove glass run from door. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Rear Door Glass Channel - Removal > Page 7890 Window Track: Service and Repair Rear Door Glass Channel - Installation INSTALLATION 1. Lower glass run into glass run door channel. 2. Install fastener (2). 3. Install door module.See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Service and Repair/Rear Door Carrier Plate - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Description and Operation Windshield: Description and Operation DESCRIPTION The windshield is attached to the window frame (fence) with urethane adhesive. The urethane adhesive is applied cold and seals the surface area between the window opening and the glass. The primer adheres the urethane adhesive to the windshield. It is difficult to salvage a windshield during the removal operation. The windshield is part of the structural support for the roof. The urethane bonding used to secure the windshield to the fence is difficult to cut or clean from any surface. If the rubber seals are set in urethane, it would also be unlikely they could be salvaged. Before removing the windshield, check the availability of the windshield and seals from the parts supplier. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal Windshield: Service and Repair Windshield - Removal REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions See: Service Precautions. 2. Remove the rear view mirror See: Body and Frame/Mirrors/Service and Repair/Interior Rearview Mirror - Removal. 3. Remove the cowl grille See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Cover - Removal CAUTION: Be careful not to damage painted surfaces when removing moldings or cutting urethane around the windshield. 4. Remove molding from the top of the windshield. 5. Using an assistant and a wire-type windshield cut-out tool (1, 3 and 4), cut and separate the urethane adhesive (2) securing the windshield to the windshield fence. 6. Carefully remove the windshield from the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal > Page 7896 Windshield: Service and Repair Windshield - Installation INSTALLATION WARNING: Do not operate the vehicle within 24 hours of windshield installation. It takes at least 24 hours for urethane adhesive to cure. If it is not cured, the windshield may not perform properly if the vehicle is in an accident. CAUTION: To help prevent water leaks, partially roll down the left and right door glass before installing the windshield. This avoids pressurizing the passenger compartment if a door is slammed before the urethane is cured. CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers. 1. If the windshield (1) is being reused, remove as much of the original urethane (3) as possible from the glass surface using a razor knife (2). NOTE: To prevent corrosion, do not damage paint on windshield fence when removing original urethane. NOTE: The windshield fence should be cleaned of most of its old urethane adhesive. A small amount of old urethane, approximately 1 mm (.04 in.) in height should remain on the fence. Do not completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Support spacers located near the cowl at the bottom of the windshield fence should be replaced with new spacers. Replace any missing or damaged spacers around the perimeter of the windshield fence. 2. Using a razor knife (2), level the original bead of urethane (1) on the windshield fence (3) to a thickness of approximately 1 mm (0.04 in.) and remove any damaged adhesive backed spacers. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal > Page 7897 3. Install new adhesive backed spacers along the windshield fence as required. 4. Install a new rubber seal (2) along the top of the windshield (1). 5. Using an assistant, position the windshield into the windshield opening and against the windshield fence (3) and spacers. 6. Verify the windshield lays evenly against the fence at the top, bottom and sides of the opening. If not, the fence must be formed to the shape of the windshield. 7. Mark the windshield and the windshield fence with a grease pencil or pieces of masking tape to use as a reference for installation. 8. Using an assistant, remove the windshield from the windshield opening and place it on a suitable padded work surface. WARNING: Do not use solvent based glass cleaners to clean the windshield before applying glass prep and primer or poor glass adhesion may result. 9. Clean the inside of the windshield with an ammonia based glass cleaner and a lint-free cloth. 10. Apply glass prep adhesion promoter 25 mm (1 in.) wide (1) around the perimeter of the windshield (2) and 5 mm (0.2 in.) from the edge of the glass and wipe dry with a clean lint-free cloth until no streaks are visible. 11. Apply glass primer 25 mm (1 in.) wide (1) around the perimeter of the windshield (2) and 5 mm (0.2 in.) from the edge of the glass. Allow at least three minutes drying time. 12. Using a flashlight, verify that the primer is completely and evenly installed along the perimeter of the windshield. 13. Re-prime any area that is not fully and evenly primed. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal > Page 7898 14. Clean the windshield fence with an ammonia based glass cleaner and a lint-free cloth. 15. Apply pinch weld primer 15 mm (0.75 in.) wide (1) around the windshield fence (2). Allow at least three minutes drying time. 16. Using a flashlight, verify that the primer is completely and evenly installed along the windshield fence. 17. Re-prime any area that is not fully and evenly primed. CAUTION: Always apply the bead of adhesive to the windshield. Always install the windshield within 5 minutes after applying the adhesive. NOTE: If the original urethane adhesive has been exposed for more than 12 hours, the entire adhesive area will need to be re-primed prior to installing new adhesive. 18. Apply approximately a 10 mm (0.4 in.) wide bead of adhesive (1) with a triangular nozzle approximately 6 mm (0.230 in.) from the edge of the glass (2) starting at the bottom center of the windshield. 19. Run the end of the adhesive bead (1) on the windshield (2) parallel to the start of the bead and smooth the ends flush. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal > Page 7899 20. Using an assistant, position the windshield (1) over the windshield opening. 21. Using the grease pencil marks or tape as reference points, align the windshield to the windshield opening. 22. Carefully lower the windshield into the windshield opening. Guide the windshield and the rubber seal (2) at the top the windshield into its proper location. CAUTION: It is not possible to move the windshield after installation. The windshield should never be pressed into place by more than one person, because the windshield can break if pressed simultaneously on both sides. 23. Push the windshield inward until the windshield comes into contact with the spacers located on each side and the bottom of the windshield fence. 24. Install the cowl grill See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Cover - Removal. 25. Install the rear view mirror onto the windshield See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Cover Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Service and Repair > Rear Washer Check Valve - Removal Check Valve: Service and Repair Rear Washer Check Valve - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Partially remove the quarter trim from the right upper D-pillar (4). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Pull the headliner (5) away from the upper liftgate opening header (1) far enough to access and disconnect the liftgate washer supply hose (6) and the headliner washer supply hose (3) from the barbed nipple on each side of the check valve (2). 4. Remove the check valve. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Service and Repair > Rear Washer Check Valve - Removal > Page 7905 Check Valve: Service and Repair Rear Washer Check Valve - Installation INSTALLATION 1. Position the rear check valve (2) between the upper liftgate opening header (1) and the headliner (5). Be certain that the raised arrow that indicates the flow direction on the center section of the valve is pointed toward the liftgate washer supply hose (6). 2. Reconnect the liftgate washer supply hose and the headliner washer supply hose (3) to the barbed nipples of the valve. 3. Reinstall the quarter trim onto the right upper D-pillar (4). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 4. Reconnect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description Wiper Switch: Description and Operation Right Multifunction Switch - Description DESCRIPTION The right (wiper) multi-function switch is located on the right side of the steering column, just below the steering wheel. This switch is the primary control for the front and rear wiper and washer systems. The only visible components of the switch are the control stalk (1), control knob (2) and control sleeve (3) that extend through the steering column shrouds on the right side of the column. The remainder of the switch including its mounting provisions and electrical connection are concealed beneath the shrouds. The switch housing and controls (6) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and is connected by a jumper wire harness (5) directly to the Steering Control Module (SCM), which is internal to the housing (2) of the left multi-function switch (1). The right (wiper) multi-function switch provides the vehicle operator with a control interface for the following wiper and washer system functions: - Continuous Front Wipers - The right multi-function switch control knob provides detent switching for two continuous front wipe modes, low speed or high speed. - Intermittent Front Wipers - The right multi-function switch control knob provides detent switching for the intermittent front wipe mode with five minor detent delay interval positions. - Front Wiper Mist Mode - The right multi-function switch control stalk includes momentary switching of the front wiper motor low speed circuit to provide a mist mode features (sometimes referred to as pulse wipe), which allows the vehicle operator to momentarily operate the front wipers for one or more complete cycles. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description > Page 7911 - Front Washer Mode - The right multi-function switch control stalk provides momentary switching for control of the front washer system operation. - Intermittent Rear Wipe Mode - The right multi-function switch control sleeve provides detent switching for a single fixed interval intermittent rear wiper mode. - Rear Washer Mode - The right multi-function switch control sleeve provides two momentary switch positions for control of rear washer system operation. The right multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description > Page 7912 Wiper Switch: Description and Operation Right Multifunction Switch - Operation OPERATION The right (wiper) multi-function switch uses a combination of resistor multiplexing and conventional switching to control the many functions and features it provides. The switch receives a clean ground from the Steering Control Module (SCM), then provides resistor multiplexed and conventional analog return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic wiper and washer switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the right multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a fail-safe mode of operation for the front and rear wiper systems. The fail-safe mode will maintain the last selected front and rear wiper system operation for the remainder of the current ignition cycle, after which both wiper systems will default to OFF. The right multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Following are descriptions of how the right multi-function switch is operated to control the many front and rear wiper and washer system functions and features it provides: - Front Wiper Control - The control knob on the end of the right multi-function switch control stalk is rotated to one of the two continuous wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The SCM reads the input from the right multi-function switch and sends electronic wiper switch status messages over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Wiper Mist Mode - The front wiper mist mode is requested when the right multi-function switch control stalk is depressed downward towards the floor to a momentary MIST position. The front wiper motor will continue to operate, one complete cycle at a time, for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Washer Control - The right multi-function switch control stalk is pulled rearward towards the steering wheel to a momentary WASH position to activate the washer pump/motor in the front washer mode. The washer pump/motor will continue to operate for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Wiper Control - The rear wiper mode is selected when the right multi-function switch control sleeve is rotated to the fixed interval intermittent rear wipe detent position, or the OFF detent position. The SCM reads the input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Washer Control - The right multi-function switch control sleeve is rotated to one of two momentary WASH positions, either fully forward or fully rearward, to activate the washer pump/motor in the rear washer mode. The washer pump/motor will continue to operate in the rear washer mode until the control sleeve is released. The SCM reads the input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 7913 Wiper Switch: Testing and Inspection RIGHT MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. The right multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the Steering Control Module (SCM) or the electronic controls or communication between other modules and devices that provide some features of the front and rear wiper and washer systems. The most reliable, efficient and accurate means to diagnose the SCM or the electronic controls and communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. 1. Remove the right multi-function switch from the integral mounting bracket on the right side of the clockspring. See: Service and Repair/Right Multifunction Switch - Removal. 2. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the three Function Tests tables. For all functions except those of the control stalk the values should be either less than 100 ohms (switch CLOSED) or greater than 1 megohm (switch OPEN). CONTROL STALK FUNCTION TESTS CONTROL KNOB FUNCTION TESTS CONTROL SLEEVE FUNCTION TESTS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 7914 3. If the switch fails any of the tests, replace the ineffective right multi-function switch as required. If the switch tests okay, but the switch input to the Steering Control Module (SCM) remains incorrect, be certain to check for a short or open in the jumper harness between the right multi-function switch and the SCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Right Multifunction Switch - Removal Wiper Switch: Service and Repair Right Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket integral to the right side of the clockspring (3) on the steering column. 4. Slide the switch away from the clockspring far enough to disengage the slide tab on the bottom of the switch housing from the channel formation in the mounting bracket. 5. Disconnect the jumper wire harness connector (1) from the connector receptacle on the inboard end of the right multi-function switch (2). 6. Remove the switch from the clockspring (3). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Right Multifunction Switch - Removal > Page 7917 Wiper Switch: Service and Repair Right Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position the right multi-function switch (2) close enough to the mounting bracket (3) integral to the right side of the clockspring to reconnect the jumper wire harness connector (1) to the connector receptacle on the inboard side of the switch housing. 2. Align the slide tab on the bottom of the switch housing with the channel integral to the clockspring mounting bracket, then slide the switch into the bracket until it is firmly seated. 3. Install and tighten the screw (2) that secures the mounting tab on the back of the right multi-function switch (1) to the mounting bracket on the clockspring (3). 4. Reinstall the upper and lower shrouds onto the steering column. See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Installation. 5. Reconnect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Windshield Washer Pump: Locations Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 7921 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 7922 Windshield Washer Pump: Diagrams Connector - (ENGINE COMPARTMENT) 2 WAY PUMP-WASHER-WINDSHIELD - (ENGINE COMPARTMENT) 2 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Description and Operation > Windshield Washer Pump - Description Windshield Washer Pump: Description and Operation Windshield Washer Pump - Description DESCRIPTION The washer pump/motor unit is located on the top of a sump area of the washer reservoir, on the forward side of the reservoir ahead of the right front strut tower in the engine compartment. A small permanently lubricated and sealed reversible electric motor (3) is coupled to the rotor-type washer pump (4). The use of an integral valve body (7) allows the washer pump/motor unit to provide washer fluid to either the front or the rear washer systems, depending upon the direction of the motor/pump impeller rotation. An inlet nipple (6) on the pump housing passes through a rubber grommet seal/filter screen installed in a dedicated mounting hole of the washer reservoir sump. The filter screen prevents most debris from entering the pump housing. When the pump is installed in the reservoir the one barbed outlet nipple (5 and 8) on the pump valve body housing connects the unit to the front washer hose, and the other barbed outlet nipple connects the unit to the rear washer hose. The washer pump/motor unit is retained on the reservoir by the interference fit between the pump inlet nipple and the grommet seal, which is a light press fit that allows for mounting of the washer pump without the use of fasteners. An integral connector receptacle (1) on the top of the motor housing connects the unit to the vehicle electrical system through a dedicated take out and connector of the engine compartment wire harness. The washer pump/motor unit cannot be repaired. If ineffective or damaged, the entire washer pump/motor unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Description and Operation > Windshield Washer Pump - Description > Page 7925 Windshield Washer Pump: Description and Operation Windshield Washer Pump - Operation OPERATION The washer pump/motor unit features a reversible electric motor. The direction of the motor is controlled by hard wired outputs from the Totally Integrated Power Module (TIPM). When battery current and ground are applied to the two pump motor terminals, the motor rotates in one direction. When the polarity of these connections is reversed, the motor rotates in the opposite direction. When the pump motor is energized, the rotor-type pump pressurizes the washer fluid and forces it through one of the two pump outlet nipples, and into the front or rear washer plumbing. The TIPM controls the hard wired outputs to the pump motor based upon electronic washer request messages received over the Controller Area Network (CAN) data bus from the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC receives electronic washer switch status messages over a Local Interface Network (LIN) bus connection from the Steering Control Module (SCM) within the left (lighting) multi-function switch housing. The SCM monitors hard wired analog and multiplex inputs from the washer switch circuitry contained within the right (wiper) multi-function switch to determine the proper electronic messages to send. Washer fluid is drawn through the pump inlet nipple from the washer reservoir to the inlet port of the washer pump housing. An integral valve body is located in a housing on the outlet port side (2) of the pump housing. A diaphragm (4) in this valve body controls which washer system plumbing receives the washer fluid being pressurized by the pump. When the pump impeller (1) rotates in the counterclockwise direction (viewed from the bottom), the biased diaphragm is sealing off the rear washer system outlet and nipple so the pressurized washer fluid is pushed out through the pump front outlet port and the front washer outlet nipple (5). When the pump impeller rotates in the clockwise direction (viewed from the bottom), pressurized washer fluid is pushed out through the pump rear outlet port and moves the diaphragm to open the rear washer outlet nipple and seal off the front washer outlet nipple, then the pressurized washer fluid is pushed out through the rear washer outlet nipple (3). The washer pump/motor unit and the hard wired motor control circuits from the TIPM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer pump/motor unit or the electronic controls or communication between other modules and devices that provide some features of the front and rear wiper and washer system. The most reliable, efficient, and accurate means to diagnose the washer pump/motor unit or the electronic controls and communication related to washer pump/motor unit operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Windshield Washer Pump - Removal Windshield Washer Pump: Service and Repair Windshield Washer Pump - Removal REMOVAL NOTE: The washer pump/motor can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Siphon the washer fluid from the washer reservoir (1) into a clean container for reuse. 3. Disconnect the engine compartment wire harness connector (2) from the washer pump/motor unit (3) connector receptacle on the top of the motor housing. 4. Disconnect the two washer hoses (4 and 5) from the two washer pump/motor unit outlet nipples. 5. Pull the washer pump/motor unit straight up and out of the washer reservoir far enough to disengage the inlet nipple from the rubber grommet seal/filter screen in the reservoir. Care must be taken not to damage the reservoir. 6. Remove the rubber grommet seal/filter screen for the washer pump from the pump mounting hole in the washer reservoir and discard. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Windshield Washer Pump - Removal > Page 7928 Windshield Washer Pump: Service and Repair Windshield Washer Pump - Installation INSTALLATION 1. Install a new rubber grommet seal/filter screen unit into the washer pump mounting hole in the washer reservoir (1). Always use a new rubber grommet seal/filter screen on the reservoir. 2. Position the inlet nipple of the washer pump (3) to the rubber grommet seal/filter screen in the washer reservoir. 3. Using hand pressure, press firmly and evenly downward on the washer pump/motor unit until the inlet nipple is fully seated in the rubber grommet seal/filter screen in the pump mounting hole of the reservoir. 4. Reconnect the two washer hoses (4 and 5) to the two barbed pump outlet nipples. Be certain that the hose in the trough on the outboard side of the reservoir is connected to the rear (black) nipple, and the hose on the inboard side of the reservoir is connected to the front (white) nipple. 5. Reconnect the engine compartment wire harness connector (2) for the washer pump/motor unit to the connector receptacle on the top of the motor housing. 6. Reconnect the battery negative cable. 7. Refill the washer reservoir with the washer fluid siphoned from the reservoir during the removal procedure. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Windshield Washer Reservoir - Description Windshield Washer Reservoir: Description and Operation Windshield Washer Reservoir Description DESCRIPTION A single washer fluid reservoir (2) is used for both the front and rear washer systems. The molded plastic washer fluid reservoir is mounted on the forward side of the right front strut tower and wheel house in the engine compartment. The filler neck extends upward into the engine compartment and a single screw installed through a mounting tab (7) on the back of the filler neck secures the unit to a stamped metal bracket on the front of the strut tower. A bright yellow plastic filler cap (1) with an International Control and Display Symbol icon for Windshield Washer molded into it snaps over the open end of the filler neck. The cap hinges on and is secured to a molded-in hook formation on the top of the mounting tab on the filler neck. There is a dedicated hole in the sump area at the lower front end of the reservoir provided for the washer pump/motor unit (5). The outboard side of the washer reservoir has an integral clip (4) and two integral troughs (6) through which the washer hoses are routed from the washer pump up into the engine compartment. An integral mounting post on the bottom of the reservoir is inserted into a hole in the horizontal front extension of the fender wheel house to locate and secure the lower end of the reservoir. An integral latch tab (3) on the upper outboard side of the reservoir engages a slot in the inboard side of the coolant reserve container (gasoline engine) or coolant pressure container (diesel engine) to aid in mounting that unit in the engine compartment. The coolant reserve container or coolant pressure container must be dismounted, but need not be removed to access the washer reservoir for service. The washer reservoir cannot be repaired and, if ineffective or damaged, it must be replaced. The washer reservoir, rubber grommet seal/filter screen for the washer pump/motor unit and the filler cap are each available for individual service replacement. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Windshield Washer Reservoir - Description > Page 7933 Windshield Washer Reservoir: Description and Operation Windshield Washer Reservoir Operation OPERATION The washer fluid reservoir provides a secure, on-vehicle storage location for a large reserve of washer fluid for operation of the front and rear washer systems. The washer reservoir filler cap provides a clearly marked and readily accessible point from which to add washer fluid to the reservoir. The washer pump/motor unit is located in a sump area near the lower forward side of the reservoir to be certain that washer fluid will be available to the pump as the fluid level in the reservoir becomes depleted. The washer pump/motor unit is mounted in the lowest position in the sump. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Windshield Washer Reservoir - Removal Windshield Washer Reservoir: Service and Repair Windshield Washer Reservoir - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove or disengage each of the fasteners that secure the coolant reserve container (gasoline engine) or the coolant pressure container (diesel engine) to the inboard side of the washer reservoir and move the container aside as necessary to gain access to the washer reservoir for removal. 3. Siphon the washer fluid from the washer reservoir (1) into a clean container for reuse. 4. Disconnect the engine compartment wire harness connector (7) from the washer pump/motor. NOTE: To aid in reinstallation, note the installed position of the washer hoses prior to disconnecting them. 5. Disconnect the front and rear washer hoses (3) from the reservoir washer hoses near the top of the right front strut tower. 6. On vehicles equipped with a diesel engine, it may be necessary to remove the screw securing the differential pressure sensor to the bracket on the front of the strut tower and move the sensor aside for access to the washer reservoir filler neck screw. Refer to EXHAUST/SENSOR, Differential Pressure for the appropriate procedures. 7. Remove the screw (2) that secures the mounting tab on the back of the reservoir filler neck to the bracket (4) on the forward side of the right front strut tower. 8. On vehicles equipped with the headlamp leveling system, it may be necessary to dismount and pull the right front lamp unit forward far enough for the front of the washer reservoir to clear the headlamp leveling motor during reservoir removal. . See: Lighting and Horns/Service and Repair/Front Lamp Unit - Removal 9. Pull the washer reservoir upward far enough to disengage the post (5) on the underside of the reservoir from the hole in the horizontal extension of the right front wheel house (6). 10. Remove the washer reservoir from the engine compartment. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Windshield Washer Reservoir - Removal > Page 7936 Windshield Washer Reservoir: Service and Repair Windshield Washer Reservoir - Installation INSTALLATION 1. Position the washer reservoir (1) into the right front corner of the engine compartment. 2. Align and engage the post (5) on the underside of the reservoir into the hole in the horizontal extension of the right front wheel house (6). 3. Install and tighten the screw (2) that secures the mounting tab on the back of the reservoir filler neck to the bracket (4) on the forward side of the right front strut tower. NOTE: Be certain to reconnect the front and rear washer hoses to the proper reservoir hoses from the washer pump. Failure to properly connect the hoses will cause the front and rear washer systems to operate incorrectly. 4. Reconnect the front and rear washer hoses (3) to the reservoir washer hoses near the top of the right front strut tower. 5. Reconnect the headlamp and dash wire harness connector (7) to the washer pump/motor unit. 6. On vehicles equipped with the headlamp leveling system, if it was necessary to relocate the right front lamp unit during reservoir removal, reinstall the lamp. . See: Lighting and Horns/Service and Repair/Front Lamp Unit - Installation 7. On vehicles equipped with a diesel engine, if it was necessary to remove the screw securing the differential pressure sensor to the bracket on the front of the strut tower and move the sensor aside for access to the washer reservoir filler neck screw, reinstall the sensor. 8. Position the coolant reserve container (gasoline engine) or the coolant pressure container (diesel engine) to the inboard side of the washer reservoir and reinstall or engage each of the fasteners that secure the container. 9. Refill the washer reservoir with the washer fluid drained during removal. 10. Reconnect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Washer Nozzle - Description Windshield Washer Spray Nozzle: Description and Operation Washer Nozzle - Description Front FRONT The fluidic front washer nozzles (2) are constructed of molded plastic and include an integral check valve. Each nozzle has two integral latches (3) that secure them in dedicated holes in the hood panel near the base of the windshield. The domed upper surface of the washer nozzle is visible on the outside of the hood panel, and the two nozzle orifices (1) are oriented towards the windshield glass. An integral diaphragm type check valve is contained within the body of each nozzle. The washer plumbing fittings (4) for the washer nozzles extend below the hood panel and are accessible from the engine compartment. The front washer nozzles cannot be adjusted or repaired and, if ineffective or damaged, they must be replaced. Rear REAR The fluidic rear washer nozzle is constructed of molded plastic. The rear washer nozzle is secured by two integral latch features (1) within a mounting hole to the right of the Center High-Mounted Stop Lamp (CHMSL) in the lower surface of the rear spoiler above the liftgate glass opening on the outer liftgate panel. The outer surface of the washer nozzle is visible on the lower exterior surface of the spoiler, and a rubber gasket (3) seals the nozzle to the spoiler mounting hole. The nozzle orifice (4) is oriented downward towards the liftgate glass. The washer plumbing fitting (2) is concealed between the spoiler and the liftgate outer panel. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Washer Nozzle - Description > Page 7941 The rear washer nozzle cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Washer Nozzle - Description > Page 7942 Windshield Washer Spray Nozzle: Description and Operation Washer Nozzle - Operation Front FRONT The two front washer nozzles are designed to dispense washer fluid into the wiper pattern area on the outside of the windshield glass. Pressurized washer fluid is fed to each nozzle from the washer reservoir by the washer pump/motor unit through a single hose, which is attached to a barbed nipple on each washer nozzle below the inner hood panel. A fluidic matrix within the washer nozzle causes the pressurized washer fluid to be emitted from the nozzle orifice as an oscillating stream to more effectively cover a larger area of the glass to be cleaned. The integral check valve in each nozzle prevents washer fluid from draining out of the washer supply hoses back to the washer reservoir. This drain-back would result in a lengthy delay after the washer switch is actuated until washer fluid was dispensed through the nozzles, because the washer pump would have to refill the washer plumbing from the reservoir to the nozzles. Such a drain-back condition could also result in water, dirt, or other outside contaminants being siphoned into the washer system through the washer nozzle orifice. This water could subsequently freeze and plug the nozzle, while other contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns. In addition, the check valve prevents washer fluid from siphoning through the washer nozzles after the washer system is turned OFF. When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing, the fluid pressure unseats a diaphragm from over a sump well within the nozzle by overriding the spring pressure applied to it by a piston. With the diaphragm unseated, washer fluid is allowed to flow toward the nozzle orifice. When the washer pump stops operating, the spring pressure on the piston seats the diaphragm over the sump well in the nozzle and fluid flow in either direction within the washer plumbing is prevented. Rear REAR The rear washer nozzle is designed to dispense washer fluid into the wiper pattern area on the outside of the liftgate glass. Pressurized washer fluid is fed to the nozzle from the washer reservoir by the washer pump/motor through a single hose, which is attached to a barbed nipple on the back of the nozzle. A fluidic matrix within the nozzle causes the pressurized washer fluid to be emitted from the nozzle orifice as an oscillating stream to more effectively cover a larger area of the glass to be cleaned. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Washer Nozzle - Removal Windshield Washer Spray Nozzle: Service and Repair Washer Nozzle - Removal Front FRONT 1. From the underside of the hood, disengage the rear edge of the silencer pad from the tabs that secure it to the inner hood reinforcement (1) as necessary to access the front washer nozzle hose connections (2). 2. Disconnect the hose connection from the barbed nipple of the front washer nozzle. 3. From the underside of the hood, release the integral latches of the front washer nozzle (2) and push the nozzle out through the mounting hole toward the top side of the hood (1). 4. Remove the nozzle from the top of the hood panel. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Washer Nozzle - Removal > Page 7945 1. Disconnect and isolate the battery negative cable. 2. Remove the fasteners that secure the spoiler (3) to the liftgate outer panel (1) See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Service and Repair/Liftgate - Removal. 3. Pull the spoiler away from the liftgate far enough to access and disconnect the liftgate washer supply hose (2) from the barbed nipple on the back of the rear washer nozzle (4). 4. From the back of the spoiler, depress the two integral latch features of the nozzle, while pulling the nozzle out through the face of the spoiler. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Washer Nozzle - Removal > Page 7946 Windshield Washer Spray Nozzle: Service and Repair Washer Nozzle - Installation Front FRONT 1. Position the front washer nozzle (2) to the mounting hole on the outside of the hood panel (1). 2. Align the anti-rotation tab of the nozzle with the anti-rotation notch in the mounting hole. 3. Using hand pressure, push firmly and evenly on the top of the nozzle until the integral latches lock into place on the underside of the hood. 4. From the underside of the hood, reconnect the washer hose connector (2) to the barbed nipple of the nozzle. 5. Reinstall the rear edge of the hood silencer pad to the clips on the inner hood reinforcement (1). Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Washer Nozzle - Removal > Page 7947 1. Position the rear washer nozzle (4) through the mounting hole from the face of the liftgate spoiler (3). 2. Using hand pressure, press the nozzle firmly and evenly into the mounting hole until the two integral latch features are fully engaged on the back of the spoiler. 3. From the back of the spoiler, reconnect the liftgate washer supply hose (2) to the barbed nipple of the nozzle. 4. Reinstall the spoiler onto the liftgate outer panel (1) See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Service and Repair/Liftgate Installation. 5. Reconnect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm - Removal Wiper Arm: Service and Repair Wiper Arm - Removal Front FRONT 1. Lift the front wiper arm (2) to its over-center position to hold the wiper blade (1) off of the glass and relieve the spring tension on the wiper arm to pivot shaft connection. 2. Carefully pry the plastic nut cap (4) off of the pivot end of the wiper arm. 3. Remove the nut (3) that secures the wiper arm to the wiper pivot shaft (5). CAUTION: The use of a battery terminal puller when removing the front wiper arm is NOT recommended as this may damage the front wiper arm. 4. Use a slight rocking action to disengage the front wiper arm pivot end from the pivot shaft and remove the wiper arm. Rear REAR 1. Lift the rear wiper arm (3) to hold the wiper blade (5) off of the glass and relieve the spring tension on the wiper arm to output shaft connection. 2. Carefully pry the plastic nut cap (1) off of the pivot end of the wiper arm. 3. Remove the nut (2) that secures the wiper arm to the rear wiper motor output shaft (4). Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm - Removal > Page 7952 CAUTION: The use of a battery terminal puller when removing the rear wiper arm is NOT recommended as this may damage the front wiper arm. 4. Use a slight rocking action to disengage the rear wiper arm pivot end from the output shaft and remove the wiper arm. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm - Removal > Page 7953 Wiper Arm: Service and Repair Wiper Arm - Installation Front FRONT NOTE: Be certain that the wiper motor is in the park position before attempting to install the front wiper arms. Turn the ignition switch to the ON position and move the right (wiper) multi-function switch control knob to its OFF position. If the wiper pivots move, wait until they stop moving, then turn the ignition switch back to the OFF position. The front wiper motor is now in its park position. 1. The front wiper arms (2) must be indexed to the pivot shafts (5) with the front wiper motor in the park position to be properly installed. Position the wiper arm pivot end onto the wiper pivot shaft so that the wiper blade (1) is aligned with the wiper alignment lines (6), which are horizontal marks concealed in the upper margin of the lower windshield blackout area. 2. Once the wiper blade is aligned, lift the wiper arm away from the windshield slightly to relieve the spring tension on the pivot end and push the pivot end of the wiper arm down firmly and evenly over the pivot shaft. 3. Install and tighten the nut (3) that secures the wiper arm to the pivot shaft. Tighten the nut to 26 Nm (19 ft. lbs.). 4. Wet the windshield glass, then operate the front wipers. Turn the wiper switch to the OFF position, then check for the correct wiper arm position and readjust as required. 5. Reinstall the plastic nut cap (4) onto the wiper arm pivot nut. Rear REAR Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm - Removal > Page 7954 NOTE: Be certain that the rear wiper motor is in the park position before attempting to install the rear wiper arm. Turn the ignition switch to the ON position and move the rear wiper switch to its OFF position. If the wiper motor output shaft moves, wait until it stops moving, then turn the ignition switch back to the OFF position. The wiper motor is now in its park position. 1. The rear wiper arm (3) must be indexed to the motor output shaft (4) with the rear wiper motor in the park position to be properly installed. Position the wiper arm pivot end onto the output shaft so that the wiper blade (5) is aligned with the lowest horizontal line of the rear window defogger grid. 2. With the rear wiper arm properly indexed, push the tapered mounting hole on the pivot end of the wiper arm down over the output shaft. 3. Install and tighten the nut (2) that secures the rear wiper arm to the rear wiper motor output shaft. Tighten the nut to 9 Nm (7 ft. lbs.). 4. Wet the liftgate glass and operate the rear wiper. Turn the rear wiper switch to the OFF position, then check for correct wiper arm position and readjust as required. 5. Reinstall the plastic nut cap over the nut on the pivot end of the rear wiper arm. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade - Removal Wiper Blade: Service and Repair Wiper Blade - Removal REMOVAL CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the wiper arm (2) to raise the wiper blade and element (6) off of the glass, until the wiper arm hinge is in its over-center position. 2. To remove the blade from the arm, depress the latch release tab (4) on the pivot block (3) under the tip of the arm and slide the blade away from the tip towards the pivot end of the arm far enough to disengage the pivot block from the hook formation (5) on the end of the arm. 3. Extract the hook formation on the tip of the wiper arm through the opening in the wiper blade superstructure (1) just ahead of the pivot block. 4. Gently lower the tip of the wiper arm onto the glass. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade - Removal > Page 7959 Wiper Blade: Service and Repair Wiper Blade - Installation INSTALLATION CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the wiper arm (2) off of the windshield glass, until the wiper arm hinge is in its over-center position. 2. Position the wiper blade near the hook formation (5) on the tip of the arm with the notched end of the wiper element flexor oriented towards the end of the wiper arm that is nearest to the wiper pivot. 3. Insert the hook formation on the tip of the arm through the opening in the blade superstructure (1) ahead of the pivot block (3) far enough to engage the pivot block into the hook. 4. Slide the pivot block up into the hook formation on the tip of the wiper arm until the latch release tab (4) snaps into its locked position. Latch engagement will be accompanied by an audible click. 5. Gently lower the wiper blade and element (6) onto the glass. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Description and Operation > Front Wiper Transmission - Description Wiper Gear Box: Description and Operation Front Wiper Transmission - Description DESCRIPTION The front wiper module is secured to stamped brackets within the cowl plenum panel beneath the cowl plenum cover/grille panel. The ends of the wiper pivot shafts protrude through dedicated openings in the cowl plenum cover/grille panel to drive the wiper arms and blades and are the only visible components of the front wiper module. The front wiper module consists of the following major components: - Bracket - The front wiper module bracket (4) consists of a long tubular steel main member that has a stamped pivot bracket formation near each end where the two wiper pivots are secured. The front wiper module bracket is secured within the cowl plenum by two screws through two rubber insulators (6). - Crank Arm - The front wiper motor crank arm (5) is a stamped steel unit with a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and a ball stud secured to the drive end. Linkage - Two stamped steel drive links (7) connect the wiper motor crank arm to the two wiper pivot lever arms. The passenger side link has a plastic socket-type bushing on each end, while the driver side link has a socket-type bushing on the pivot end and a sleeve-type bushing on the crank arm end. The bushing on the pivot end of each link is snap-fit over a ball stud on the pivot lever arm. The sleeve-type bushing on the driver side link is snap fit over the inner ball formation of a double ball stud on the crank arm, then the socket-type bushing of the passenger side drive link is snapped over the outer ball formation. - Motor - The front wiper motor (9) is secured by a bracket (3) integral to the motor transmission housing with two screws and nuts near the center of the wiper module bracket. A knob-like rubber insulator (8) on a stud integral to the motor transmission housing is engaged in a slot in a stamped bracket on the forward wall of the cowl plenum. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting circuit breaker. - Pivots - The two front wiper pivots (1) are secured to the ends of the wiper module bracket. The lever arms that extend from the bottom of the pivot shafts each have ball-studs that engage the bushings of the drive links. A molded plastic shield (2) is fit over the top of each pivot housing. The upper end of each pivot shaft where the wiper arms will be fastened each is tapered and serrated with a threaded stud formation at the tip. The front wiper motor and crank arm unit is available for separate service replacement. Any other component of the front wiper module cannot be adjusted or repaired. If any component of the module other than the motor is ineffective or damaged, the entire front wiper module unit must be replaced. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Description and Operation > Front Wiper Transmission - Description > Page 7964 Wiper Gear Box: Description and Operation Front Wiper Transmission - Operation OPERATION The front wiper module operation is controlled by the battery current inputs received by the wiper motor through the Totally Integrated Power Module (TIPM). The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately closes the wiper park switch sense circuit to ground or to battery current, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned OFF, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. The hard wired inputs and outputs of the front wiper motor may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the front wiper motor or the electronic controls or communication between other modules and devices that provide some features of the front wiper and washer system. The most reliable, efficient, and accurate means to diagnose the front wiper motor or the electronic controls and communication related to front wiper motor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Front Wiper Transmission - Removal Wiper Gear Box: Service and Repair Front Wiper Transmission - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove both front wiper arms from the wiper pivots. . See: Wiper Arm/Service and Repair/Wiper Arm - Removal 3. Remove the cowl plenum cover/grille panel from over the front wiper module. 4. Disengage the routing clip (2) from the stud in the cowl plenum and disconnect the wire harness (1) connector from the connector receptacle for the front wiper motor (3). 5. Remove the two screws (2) that secure the ends of the front wiper module bracket (3) to the stamped brackets (1) within the cowl plenum. 6. Pull the front wiper module inboard far enough to disengage the knob-like rubber isolator from the slotted bracket (4) on the forward wall of the cowl plenum. 7. Remove the front wiper module from the cowl plenum as a unit. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Front Wiper Transmission - Removal > Page 7967 Wiper Gear Box: Service and Repair Front Wiper Transmission - Installation INSTALLATION 1. Position the front wiper module (3) into the cowl plenum as a unit. 2. Position the knob-like rubber isolator to the slotted bracket (4) on the forward wall of the cowl plenum and pull the module outboard far enough to seat the isolator in the bracket. 3. Loosely install the two screws (2) that secure the ends of the front wiper module bracket to the stamped brackets (1) within the cowl plenum. 4. Tighten the two screws, driver side followed by passenger side. 5. Reconnect the wire harness (1) connector to the connector receptacle for the front wiper motor (3) and engage the routing clip onto the stud in the cowl plenum. 6. Reinstall the cowl plenum cover/grille panel over the front wiper module. NOTE: Be certain to turn the ignition switch to the ON position, then turn the front wiper switch ON and OFF again to cycle the wiper motor and linkage to their natural park position before reinstalling the front wiper arms onto the wiper pivots. 7. Reinstall both front wiper arms onto the wiper pivots. . See: Wiper Arm/Service and Repair/Wiper Arm - Installation 8. Reconnect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Front Wiper Motor Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Front Wiper Motor > Page 7972 Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Front Wiper Motor (Engine Compartment) 5 Way Wiper Motor: Diagrams Front Wiper Motor (Engine Compartment) 5 Way Connector - (ENGINE COMPARTMENT) 5 WAY MOTOR-WIPER-FRONT - (ENGINE COMPARTMENT) 5 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Front Wiper Motor (Engine Compartment) 5 Way > Page 7975 Wiper Motor: Diagrams Rear Wiper Motor (Liftgate) 4 Way Connector - (LIFTGATE) 4 WAY MOTOR-WIPER-REAR - (LIFTGATE) 4 WAY Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation > Wiper Motor - Description Wiper Motor: Description and Operation Wiper Motor - Description DESCRIPTION The rear wiper motor (4) is concealed within the liftgate, below the liftgate glass and behind the liftgate inner trim panel. The end of the motor output shaft (2) that extends through the lower edge of the liftgate glass to drive the rear wiper arm and blade is the only visible component of the rear wiper motor. A rubber grommet is engaged within the output shaft hole of the liftgate glass and seals the output shaft where it passes through the glass. An integral connector receptacle (3) connects the rear wiper motor to the vehicle electrical system through a dedicated take out and connector of the liftgate wire harness. The rear wiper motor consists of the following major components: - Bracket (5) - The rear wiper motor bracket consists of a stamped metal mounting plate for the wiper motor that is secured to the wiper motor housing, and through three screws with rubber isolators (1) to the liftgate inner panel. - Motor - The single-speed permanent magnet rear wiper motor is secured to the rear wiper motor bracket. The wiper motor includes an integral transmission, motor output shaft, automatic resetting circuit breaker and the rear wiper motor park switch. The rear wiper motor cannot be adjusted or repaired. If any component of the motor is ineffective or damaged, the entire rear wiper motor unit must be replaced. The motor output shaft rubber grommet is available for individual service replacement. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation > Wiper Motor - Description > Page 7978 Wiper Motor: Description and Operation Wiper Motor - Operation OPERATION The rear wiper motor operation is controlled by the Totally Integrated Power Module (TIPM), which uses intelligent, high current, self-protected high side switches to control rear wiper system operation for energizing or de-energizing the rear wiper motor. The TIPM uses internal programming and electronic messages received over the Controller Area Network (CAN) data bus from the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) to provide the appropriate rear wiper and washer system operating modes. The EMIC uses electronic messages received from the Steering Control Module (SCM) over a Local Interconnect Network (LIN) data bus to determine when to send electronic rear wiper system requests to the TIPM. The rear wiper motor park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately closes and opens a path to ground for the rear wiper motor electronic control logic circuitry of the TIPM, depending upon the position of the rear wiper blade on the liftgate glass. This input allows the electronic logic circuits of the TIPM to control all of the electronic features of rear wiper motor operation and to keep the motor energized long enough to complete its current wipe cycle and park the wiper blade after the wiper system or the ignition switch has been turned OFF. The rear wiper motor is grounded at all times through a take out with an eyelet terminal connector in the body wire harness that is secured to a ground location in the passenger compartment. The automatic resetting circuit breaker protects the motor from overloads. The rear wiper motor transmission converts the rotary output of the wiper motor to the back and forth wiping motion of the rear wiper arm and blade on the liftgate glass. The hard wired inputs and outputs of the rear wiper motor may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the rear wiper motor or the electronic controls or communication between other modules and devices that provide some features of the rear wiper and washer system. The most reliable, efficient, and accurate means to diagnose the rear wiper motor or the electronic controls and communication related to rear wiper motor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Removal Wiper Motor: Service and Repair Wiper Motor - Removal Front REMOVAL CAUTION: Do not apply pressure to, or pry on, the plastic drive link bushings. When removing the drive link from, or installing the drive link to the ball stud on the wiper motor crank arm, apply pressure to, or pry on, only the metal portions of the drive link around the bushing. If the bushing is damaged, the entire front wiper module MUST be replaced. CAUTION: Do not remove the crank arm nut from the wiper motor output shaft. The crank arm is indexed to the output shaft with the motor in the park position during the manufacturing process, but there are no provisions made for correctly indexing this connection in the field. If the crank arm to output shaft indexing is incorrect, the entire front wiper module MUST be replaced. 1. Disconnect and isolate the battery negative cable. 2. Remove the front wiper module (1) from the vehicle. See: Wiper Gear Box/Service and Repair/Front Wiper Transmission - Removal. 3. Disengage the socket bushing (3) of the passenger side wiper drive link from the ball stud on the wiper motor crank arm (4) using two large screwdrivers, one on each side of the ball stud. Pry firmly and evenly between the crank arm and the metal portion of the drive link until the socket unsnaps from the ball. 4. Remove the sleeve bushing (2) of the driver side wiper drive link from the ball stud on the wiper motor crank arm. 5. Remove the two screws (2) that secure the motor bracket (4) to the module bracket (1). 6. Remove the wiper motor and crank arm unit (5) from the underside of the module bracket. Rear Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Removal > Page 7981 REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear wiper arm from the rear wiper motor output shaft. . See: Wiper Arm/Service and Repair/Wiper Arm - Removal 3. Remove the trim from the liftgate inner panel See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal. 4. Disconnect the liftgate wire harness connector (2) from the rear wiper motor (4). 5. Remove the three screws (3) that secure the motor mounting bracket to the U-nuts (5) on the liftgate inner panel. 6. Pull the wiper motor forward far enough to disengage the output shaft from the rubber grommet (1) in the liftgate glass. 7. Remove the motor from the liftgate. 8. Remove the rubber grommet from the output shaft clearance hole in the liftgate glass and discard. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Removal > Page 7982 Wiper Motor: Service and Repair Wiper Motor - Installation Front INSTALLATION CAUTION: Do not apply pressure to, or pry on, the plastic drive link bushings. When removing the drive link from, or installing the drive link to the ball stud on the wiper motor crank arm, apply pressure to, or pry on, only the metal portions of the drive link around the bushing. If the bushing is damaged, the entire front wiper module MUST be replaced. CAUTION: Do not remove the crank arm nut from the wiper motor output shaft. The crank arm is indexed to the output shaft with the motor in the park position during the manufacturing process, but there are no provisions made for correctly indexing this connection in the field. If the crank arm to output shaft indexing is incorrect, the entire front wiper module MUST be replaced. 1. Position the front wiper motor and crank arm unit (5) to the underside of the front wiper module bracket (1). 2. Install and tighten the two screws (2) into the two nuts (3) that secure the motor bracket (4) to the module bracket. 3. Position the sleeve bushing (2) of the driver side wiper drive link onto the ball stud on the end of the motor crank arm (4). 4. Position the socket bushing (3) of the passenger side wiper drive link over the ball stud on the crank arm. 5. Place a short 19 millimeter or 3/4 inch socket over the domed cap side of the socket bushing as an installation tool. Use large channel-lock pliers to firmly and evenly apply enough pressure to the underside of the crank arm and the top of the socket installation tool to snap the bushing onto the ball stud. Do not apply pressure directly to the plastic bushings. NOTE: Be certain to turn the ignition switch to the ON position, then turn the front wiper switch ON and OFF again to cycle the wiper motor and linkage to their natural park position before reinstalling the front wiper arms onto the wiper pivots. 6. Reinstall the front wiper module (1) into the vehicle. See: Wiper Gear Box/Service and Repair/Front Wiper Transmission - Installation. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Removal > Page 7983 7. Reconnect the battery negative cable. Rear INSTALLATION 1. Install a new rubber grommet (1) into the rear wiper motor output shaft clearance hole located in the liftgate glass. Always use a new rubber grommet in the glass. 2. Check to be certain that the three U-nuts (2) are properly installed and in good condition in the liftgate inner panel (3). CAUTION: A new replacement rear wiper motor is shipped with a rubber lubricant applied to the motor output shaft where it contacts the rubber grommet in the liftgate glass. If a rear wiper motor is removed then reinstalled, an appropriate rubber lubricant (Mopar(R) Nye Synthetic Lubricant - also known as Fluorocarbon Gel 880 Synthetic Lubricant) must be applied to the motor output shaft in the area just below the taper where the shaft will contact the grommet before the motor is reinstalled. Failure to comply with this caution can result in premature grommet failure, excessive motor loads and water leaks. 3. Insert the rear wiper motor (4) output shaft through the rubber grommet (1) in the liftgate glass. 4. Position the rear wiper motor and mounting bracket to the U-nuts (5) in the liftgate inner panel as a unit 5. Install and tighten the three screws (3) that secure the motor mounting bracket to the liftgate. 6. Reconnect the liftgate wire harness connector (2) to the wiper motor connector receptacle. 7. Reinstall the trim onto the liftgate inner panel See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Installation. 8. Reinstall the rear wiper arm onto the output shaft. . See: Wiper Arm/Service and Repair/Wiper Arm - Installation 9. Reconnect the battery negative cable. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description Wiper Switch: Description and Operation Right Multifunction Switch - Description DESCRIPTION The right (wiper) multi-function switch is located on the right side of the steering column, just below the steering wheel. This switch is the primary control for the front and rear wiper and washer systems. The only visible components of the switch are the control stalk (1), control knob (2) and control sleeve (3) that extend through the steering column shrouds on the right side of the column. The remainder of the switch including its mounting provisions and electrical connection are concealed beneath the shrouds. The switch housing and controls (6) are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. A single screw (7) through a mounting tab integral to the back of the switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring (3). A single connector receptacle containing seven terminal pins is integral to the inboard end of the switch housing and is connected by a jumper wire harness (5) directly to the Steering Control Module (SCM), which is internal to the housing (2) of the left multi-function switch (1). The right (wiper) multi-function switch provides the vehicle operator with a control interface for the following wiper and washer system functions: - Continuous Front Wipers - The right multi-function switch control knob provides detent switching for two continuous front wipe modes, low speed or high speed. - Intermittent Front Wipers - The right multi-function switch control knob provides detent switching for the intermittent front wipe mode with five minor detent delay interval positions. - Front Wiper Mist Mode - The right multi-function switch control stalk includes momentary switching of the front wiper motor low speed circuit to provide a mist mode features (sometimes referred to as pulse wipe), which allows the vehicle operator to momentarily operate the front wipers for one or more complete cycles. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description > Page 7988 - Front Washer Mode - The right multi-function switch control stalk provides momentary switching for control of the front washer system operation. - Intermittent Rear Wipe Mode - The right multi-function switch control sleeve provides detent switching for a single fixed interval intermittent rear wiper mode. - Rear Washer Mode - The right multi-function switch control sleeve provides two momentary switch positions for control of rear washer system operation. The right multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring (with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness are each available for separate service replacement. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Right Multifunction Switch - Description > Page 7989 Wiper Switch: Description and Operation Right Multifunction Switch - Operation OPERATION The right (wiper) multi-function switch uses a combination of resistor multiplexing and conventional switching to control the many functions and features it provides. The switch receives a clean ground from the Steering Control Module (SCM), then provides resistor multiplexed and conventional analog return outputs to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic wiper and washer switch request messages over the Controller Area Network (CAN) data bus to other electronic modules in the vehicle. If the SCM detects no inputs from the right multi-function switch, it transmits an electronic Signal Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to request other electronic modules to implement a fail-safe mode of operation for the front and rear wiper systems. The fail-safe mode will maintain the last selected front and rear wiper system operation for the remainder of the current ignition cycle, after which both wiper systems will default to OFF. The right multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, the most reliable, efficient and accurate means to diagnose this component requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Following are descriptions of how the right multi-function switch is operated to control the many front and rear wiper and washer system functions and features it provides: - Front Wiper Control - The control knob on the end of the right multi-function switch control stalk is rotated to one of the two continuous wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The SCM reads the input from the right multi-function switch and sends electronic wiper switch status messages over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Wiper Mist Mode - The front wiper mist mode is requested when the right multi-function switch control stalk is depressed downward towards the floor to a momentary MIST position. The front wiper motor will continue to operate, one complete cycle at a time, for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Front Washer Control - The right multi-function switch control stalk is pulled rearward towards the steering wheel to a momentary WASH position to activate the washer pump/motor in the front washer mode. The washer pump/motor will continue to operate for as long as the control stalk is held in this position. The SCM reads the resistor multiplexed input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Wiper Control - The rear wiper mode is selected when the right multi-function switch control sleeve is rotated to the fixed interval intermittent rear wipe detent position, or the OFF detent position. The SCM reads the input from the right multi-function switch and sends an electronic wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other electronic modules in the vehicle. - Rear Washer Control - The right multi-function switch control sleeve is rotated to one of two momentary WASH positions, either fully forward or fully rearward, to activate the washer pump/motor in the rear washer mode. The washer pump/motor will continue to operate in the rear washer mode until the control sleeve is released. The SCM reads the input from the right multi-function switch and sends an electronic washer switch status message over the LIN data bus to the EMIC, which relays an electronic washer switch request message over the CAN data bus to other electronic modules in the vehicle. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 7990 Wiper Switch: Testing and Inspection RIGHT MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. The right multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the Steering Control Module (SCM) or the electronic controls or communication between other modules and devices that provide some features of the front and rear wiper and washer systems. The most reliable, efficient and accurate means to diagnose the SCM or the electronic controls and communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. 1. Remove the right multi-function switch from the integral mounting bracket on the right side of the clockspring. See: Service and Repair/Right Multifunction Switch - Removal. 2. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the three Function Tests tables. For all functions except those of the control stalk the values should be either less than 100 ohms (switch CLOSED) or greater than 1 megohm (switch OPEN). CONTROL STALK FUNCTION TESTS CONTROL KNOB FUNCTION TESTS CONTROL SLEEVE FUNCTION TESTS Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 7991 3. If the switch fails any of the tests, replace the ineffective right multi-function switch as required. If the switch tests okay, but the switch input to the Steering Control Module (SCM) remains incorrect, be certain to check for a short or open in the jumper harness between the right multi-function switch and the SCM. Dodge Caliber Workshop Manual (L4-2.4L (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Right Multifunction Switch - Removal Wiper Switch: Service and Repair Right Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove both the upper and lower shrouds from the steering column See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal and See: Steering and Suspension/Steering/Steering Column/Steering Column Cover/Service and Repair/Steering Column Shroud - Removal. 3. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket integral to the right side of the clockspring (3) on the steering column. 4. Slide the switch away from the clockspring far enough to disengage the slide tab on the bottom of the switch housing from the channel formation in the mounting bracket. 5. Disconnect the jumper wire harness connector (1) from the connector receptacle on the inboard end of the right multi-function switch (2). 6. Remove the switch from the clockspring (3).